101402-3882 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023882

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3882 1014023882

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Buy INJECTION-PUMP ASSEMBLY 101402-3882 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3882 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9220

3. GOVERNOR 105404-5180

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) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3882 as INJECTION-PUMP ASSEMBLY

108822-3287 as _

Cross reference number

ZEXEL 101402-3882 1014023882

Zexel num

Bosch num

Firm num

Name

101402-3882

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 9.4

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 90 89 91

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 480 480 480

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

Fixing the lever *

Rack limit *

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT
----------
K=12
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)At hole above R = aa (center) (2)Speed = bb (push-button power increase) (3)Speed = cc (active mode).
----------
aa=80mm bb=1200r/min cc=1150r/min
----------
a=(34deg)+-5deg b=(17deg)+-3deg c=32deg+-3deg d=(3deg)+-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:

Product smu Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000 100% 7.0 0 0 0 0
4001-8000 50% 3.5 0 0 50% 0
This is a 7.0?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.Test 1: Use "Test for CylinderCutout" to determine if individual injector replacements (using originalinjector part) are needed.Test 2: Use "Test for Leakagefrom Poppet Valve" to determine if full injector sets (using new injectorparts and a software change from the table) are appropriate for repair.Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine will need to be diagnosed by othermethods.
Cut out one bank of cylinders.
Engine rpm and the fuel positionon the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from Poppet Valve:
Warm engine out of Cold Mode to normaloperating temperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
!Personal injury can result from hot oil and components. Do not allowhot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port are an indication ofexcessive poppet valve leakage.
If multiple injectors are discovered with excessiveleakage from the poppet valve, update the full set of injectors and softwarewith the new version given in this Service Letter. Install new seals forthe injector and the jumper tube during this repair. The injector repairprocedure can be found in Special Instruction REHS0116. The old softwarepart number should be documented for potential future reference.
Before proceeding with updating