101402-3820 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023820

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3820 1014023820

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101402-3820 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3820 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5070

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3820 as INJECTION-PUMP ASSEMBLY

108622-3830 as _

Cross reference number

ZEXEL 101402-3820 1014023820

Zexel num

Bosch num

Firm num

Name

101402-3820

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 2.5 2.45 2.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 9.8

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 69.5 68.5 70.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 48.7 48.7

Boost pressure mmHg 365 365

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 385 385 385

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position 9.6

Boost pressure kPa 24.7 23.4 26

Boost pressure mmHg 185 175 195

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position 10.6

Boost pressure kPa 38 34 42

Boost pressure mmHg 285 255 315

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (When hydraulic cylinder is OFF) (5)Boost compensator stroke: BCL (6)When hydraulic cylinder ON: P1 (7)Rack difference between N = N1 and N = N2
----------
K=13 BCL=1+-0.1mm P1=((392)kPa{(4)kgf/cm2}) N1=1200r/min N2=800r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min

Information:

Problem
Some connecting rod assemblies may have been machined incorrectly. A machining discrepancy in the rod eye bore may not allow the rod eye bushing outside diameter to make complete contact with the rod eye bore. This can reduce the life of the bushing.
Affected Product
Model & Identification Number
3508 (7YG2069, 95Y1016, 96Y1725-1727, 23Z6865, 23Z6867-6871, 23Z6884-6885, 23Z6889, 23Z6892, 68Z903-906, 68Z909 , 68Z912, 68Z914, 69Z745-761)
3508B (7SM77, 7SM82-83)
G3508 (9TG141-144)
3512 (49Y835, 51Y760, 24Z7930-7932, 24Z7935-7948, 24Z7951, 24Z7953-7965, 24Z7969, 24Z7971, 24Z7980-7982, 24Z7985, 24Z7990-7991, 66Z718-721, 66Z1444-1445)
3512B (4TN99, 8RM201-202, 6WN137, 6FL145)
G3512 (7NJ287-290, 7NJ297)
3516 (5SJ542-543, 7CL416, 7CL419-421, 4XF673, 25Z5550-5551, 25Z5553-5555, 25Z5559, 25Z5567, 25Z5569-5574, 25Z5577, 25Z5584-5585, 28Z646, 29Z1227-1230, 67Z1447-1449)
3516B (9AN121, 8KN146-149, 8KN153-154, 7RN464-470)
G3516 (8LD46, 4EK1304-1305, 4EK1307-1313, 4EK1327, 4EK1334)
777D (3PR466-468, 3PR472-478, 3PR480)
Parts Needed
1 - 6I1356 Seal1 - 6I1357 Seal1 - 1013281 Rod Assembly1 - 1077330 Bearing (if necessary)1 - 1106991 Gasket-Head1 - 1106992 Gasket The parts are listed as one per failure. As many as 8, 12, or 16 parts may be required depending on the engine model. Additional parts not listed may be required depending on arrangement.
Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Labor Hour Breakdown For repairs of less than a complete set, 6.0 hours of labor per cylinder are reimbursable.
Allow 1.0 hour labor for testing of an engine and an additional 2.0 hours for setup/tear down.
The rod inspection, rod replacement and engine testing setup/tear down labor hours listed above are based on a basic 3500 Series Commercial Engine repaired in a dealer shop. Engines with various attachments, at customer sites or in a vehicle chassis may require additional labor hours. Those additional hours must be explained in the claim details.Costs incurred for emergency parts orders, for return of connecting rods, oil analysis, equipment needs to complete repairs or engine testing should be listed as other expenses and explained.
Parts Disposition
Return the removed defective connecting rod(s) to:
Caterpillar, Inc.
Attn: Jack Sanders - PI3047
Building B Claims Room
3701 State Road 26 East
Lafayette, Indiana 47905
Package the defective connecting rod(s) in it's original packaging carton for return shipment to Lafayette. Return defective parts within 24 hours of completion of removal from the engine. Call Matt Hannon at (765) 448-5138 or e-mail HANNOMJ with shipping Bill Number, part number, quantity in shipment, and Dealer name and location.
Dealers outside of North America should ship by Air Freight.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Connecting Rod Inspection
- The inspection of the connecting rod date code can be performed by removing the cylinder block side covers (left side typically most accessible) and viewing the date code. Rotation of the crankshaft and use of a mirror and a flash light will assist in viewing the date code on some rods. The date code is located on the side of the side of the rod cap at cap to rod joint. The date code format is YYMXXXX where (YY) is the year, (M) is a letter denoting the month, and (XXXX) is a sequence number. Rods with date