101402-3860 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023860

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3860 1014023860

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Buy INJECTION-PUMP ASSEMBLY 101402-3860 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3860 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9270

3. GOVERNOR 105404-5210

4. SUPPLY PUMP

105220-5960

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)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3860 as INJECTION-PUMP ASSEMBLY

108822-3294 as _

Cross reference number

ZEXEL 101402-3860 1014023860

Zexel num

Bosch num

Firm num

Name

101402-3860

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 10

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 76 75 77

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13.5 12.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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 *

Rack limit *

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)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (5)The torque control spring must does not have a set force. (6)Rack difference between N = N1 and N = N2 (7)Rack difference between N = N3 and N = N4
----------
K=11 N1=1250r/min N2=700r/min N3=1250r/min N4=400r/min
----------

Speed control lever angle

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

----------
a=15deg+-5deg b=32deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
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=16.5deg bb=0deg
----------
a=54deg54min+-3deg b=8deg15min+-30min

Information:

This Program must be administered as soon as possible. When reporting the repair, use "PI3325" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3325" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
February 29, 2000Termination Date
February 29, 2000Problem
Upgrade software needs to be installed on certain 3606, 3608, 3612, and 3616 diesel engines with the Marine Monitoring System (MMS) to become Y2K compatible.
Affected Product
Model & Identification Number
3606 (8RB29, 8RB656-661, 8RB669, 8RB672-673, 8RB680-688, 8RB691-00692, 8RB695-702, 8RB711-00713, 8RB715, 8RB717-718, 8RB721-723)
3608 (6MC535-536, 6MC550, 6MC561-562, 6MC582-586)
3612 (9RC230, 9RC242, 9RC247-253, 9RC256-257, 9RC259-260)
3616 (1PD289-293, 1PD295, 1PD306, 1PD308, 1PD313-336)
Parts Needed
- Dealers will need to obtain the Upgrade Files for this program.- 1 Blank formatted 1.44 MB floppy disk for Winfile Upgrade- 6 Blank formatted 1.44 MB floppy disks for InTouch 5.6B UpgradeAction Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
This is a 1-hour job.
U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(1-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Windows 3.11 Winfile Upgrade
This upgrade is necessary for Windows 3.11 to correctly date stamp files after the year 2000, The first three steps in the following procedure will be done in the office or shop.
1. Obtain the file. The file can be obtained from the Caterpillar Mailbox, SISWEB, or from the SIS disks that are released monthly. The file part number is 174-8693.2. Unzip the file. The 174-8693.exe file is a self-executing zip file. To Unzip, place the file in a known location on the hard drive. Run the file. At the dialog box type in 'A:\' where it asks for the folder to place unzipped files. Install a blank formatted disk into the A: drive. Select UNZIP or press "ENTER". This will unzip the files to the floppy drive. If your floppy drive is not 'A:' substitute your floppy drive letter for A in the above instuctions.)
3. Label the disk. This disk should be labeled "Winfile.exe Y2K Upgrade". This disk or a copy of this disk can be used to do multiple upgrades. It is not necessary to repeat steps 1-3 for each upgrade.4. Perform the upgrade. The upgrade should be done from the DOS prompt. Attach a keyboard to the MMS computer. With the MMS program running press "ALT"and "F4" at the same time. This will exit the MMS program. Press "ALT"and "F4" at the same time again and you will get a dialog box that asks you to confirm you want to end your Windows session. Press "ENTER" to confirm. Install the floppy labeled "Winfile.exe Y2K Upgrade" into the floppy drive on the MMS