101402-3821 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023821 6732711140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3821 1014023821

KOMATSU 6732711140 6732711140

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Buy INJECTION-PUMP ASSEMBLY 101402-3821 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3821 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5071

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:

101402-3821 as INJECTION-PUMP ASSEMBLY

108622-3840 as _

Cross reference number

ZEXEL 101402-3821 1014023821

KOMATSU 6732711140 6732711140

Zexel num

Bosch num

Firm num

Name

101402-3821
101402-3822

6732711140 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E * K

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 11.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 91.5 90.5 92.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 410 410 410

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. 65 65 75

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 R1-0.65

Boost pressure kPa 20 18.7 21.3

Boost pressure mmHg 150 140 160

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(11.5)

Boost pressure kPa 30.7 24 37.4

Boost pressure mmHg 230 180 280

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Boost compensator stroke: BCL (7)When the hydraulic cylinder is ON (P1)
----------
K=10 BCL=0.65+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------

Speed control lever angle

F:Full speed I:Idle (1)- (2)Stopper bolt setting
----------

----------
a=14deg+-5deg b=27deg+-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=15.5deg bb=0deg
----------
a=54deg54min+-3deg b=7deg45min+-30min

Information:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5331" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
October 31, 1998Problem
Some 3116 and 3126 HEUI Engines may have excessive oil consumption as a result of oil leaking past the intensifier piston o-ring inside the injector. Engine oil consumption becomes excessive and may increase rapidly. There are no traditional signs of oil consumption, smoke, blow-by, etc. The engine has no performance problem, has good power and normal exhaust smoke.
The problem seems to be very low frequency and is not batch related.
Affected Product
Model & Identification Number
3116 (8WL1-Up)
3126 (1WM1-Up 4ES1-Up )
Parts Needed
3116 Engines6 - 1162784 Injectors (for 170 Hp)6 - 1166706 Injectors (for 185, 195, 215, 230, 250 and 275 Hp) 3126 Engines6 - 0R4970 Injectors (for 230, 250, 275, 300 and 330 Hp)6 - 0R4972 Injectors (for 175, 190 and 210 Hp)Action Required
See the attached rework procedure.
Service Claim Allowances
Labor Hour Breakdown TK = TopKickMC = Medium Hood ConventionalClaim 1290-500 for an additional 1.6 hours if the repair is made in a motor home chassis, cab type (RV), or bus chassis, cab type (BU).
Parts Disposition
TEPS/MEPS Dealers must return the affected part(s) to their Caterpillar dealer.
Parts must be returned undamaged in the original shipping boxes to:
Caterpillar Inc.
Attn: Michael Mosley - PS5331
8401 N. University
Peoria, Illinois 61615
Injectors must be sealed in a plastic bag to prevent fuel from leaking out during shipment.
A clear, legible copy of the service report in a plastic page protector must be included in the box with the returned injectors. The report must be packaged to arrive free of oil, grease and diesel fuel.
Attach.(1 - Rework Procedure)Rework Procedure
Check to see if PS8826 (Jumper-tube Rework) is to be applied to the affected engine. Perform PS8826 if it has not been performed prior to oil consumption test.
Document the oil consumption for 30 days using the attached Oil Consumption Test Sheet, Form Number 01-081227.
All of the following steps must be followed in order to establish base line data for oil consumption for full warranty reimbursement.
1. Change oil and filter at the beginning of the test to establish base line at normal change interval. Use CG-4 oil and new oil filter. Oil and filter are not claimable under this letter.
2. Refill with the proper amount of oil; 27liters/29 quarts, and 18 liters/19 quarts per the July 1997 Operations Maintenance Manual.3. Inspect for external leaks around the gaskets and the front and rear main seals.4. Inspect the air compressor air tanks for excess oil.5. Inspect the turbo oil drain line for excessive oil indicating seal leak.6. At the completion of