101482-9200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9200 1014829200

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Service parts 101482-9200 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8150

3. GOVERNOR 105419-1410

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-6020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4710

11. Nozzle and Holder 16600-54T01

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3390

14. NOZZLE

105017-0900

15. NOZZLE SET

Include in #1:

101482-9200 as INJECTION-PUMP ASSEMBLY

104302-6600 as _

Cross reference number

ZEXEL 101482-9200 1014829200

Zexel num

Bosch num

Firm num

Name

101482-9200

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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.2 3.15 3.25

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 10.4

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 42.7 41.7 43.7

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 38.4 36.4 40.4

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 9.2+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 8 6 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 62 72

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)RACK LIMIT (4)Main spring setting (5)Set idle sub-spring
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the stopper bolt at delivery
----------

----------
a=(24deg)+-5deg b=(14deg)+-5deg c=(3deg)+-5deg

Stop lever angle

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

----------
a=56.5deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=7.7mm
----------
a1=B a2=- a3=- a4=- r1=1000r/min r2=- r3=- r4=- Q1=42.7+-1mm3/st Q2=- Q3=- Q4=- c1=+-3.5% c2=- c3=- c4=- a5=23 a6= a7=18 a8=- a9=- a10=- a11=- a12=- a13=- a14=- a15=- r5=1165r/min r6=1105r/min r7=900r/min r8=- r9=- r10=- r11=- r12=- r13=- r14=- r15=- R5=1245+-25r/min R6=1185+-25r/min R7=965+-25r/min R8=- R9=- R10=- R11=- R12=- R13=- R14=- R15=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(100deg)

Information:

AFFECTED PRODUCT
Model Identification Number
993K Z4D00179-00182
PARTS NEEDED
Qty
Part Number Description
2 1R1808 FILTER-LUBE
12 8S9191 BOLT
4 3460335 CLAMP-BAND
12 3594060 INJECTOR GP-FUEL
1 BULK_OIL DEO-ULS (120 Liters)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
If excessive fuel dilution of engine oil is found reference the following to determine the cause of fuel dilution.
Special Instruction, REHS3007,"Determining the Cause of Fuel Dilution of Engine Oil"
Troubleshooting, KENR9795, "C27 and C32 Engines for Caterpillar Built Machines"
Once an injector(s) has been identified as having a cracked/leaking injector body, replace the failed injector(s). Inspect the remaining good injector serial numbers with Cat ET, (Injector Serial Numbers = Injector trim file name, (ie 6Cxxxxxxxxxx.trm)). If the remaining injector serial numbers fall within the serial number range below, replace at the same time. Refer to Image 1 for the serial number location on the top of the electronic unit injector.
Injector Serial Numbers
6C001793971D through 6C002198297C
If an injector failure occurs on either of the rear two cylinders (right and/or left hand bank) the exhaust piping going from the turbo to the CEM will have to be removed. 346-0335 Exhaust Clamp cannot be reused and MUST be replaced with a new clamp. Refer to REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for the proper installation and removal procedure. Refer to Image 2 for clamp location.
The 8S-9191 Injector Hold Down Bolts must be replaced.
Refer to Disassembly and Assembly, RENR9217 for the removal, installation, and tightening procedures.
After the engine is reassembled, change the engine oil and filters.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 10.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.