Information injection-pump assembly
ZEXEL
101491-1020
1014911020
Rating:
Cross reference number
ZEXEL
101491-1020
1014911020
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4620
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
64.5
63.5
65.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
7.5
6.2
8.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.6+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60.5
60.5
65.5
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1500
Advance angle
deg.
1.5
1.2
1.8
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
3
3
3
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)The torque control spring must does not have a set force.
(4)Torque spring does not operate.
(5)Rack difference between N = N1 and N = N2
(6)Idle sub spring setting: L1.
----------
K=6 N1=1000r/min N2=400r/min L1=8.9+-0.1mm
----------
----------
K=6 N1=1000r/min N2=400r/min L1=8.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Pump speed = bb
(3)Stopper bolt setting
----------
aa=1550r/min bb=1000r/min
----------
a=10deg+-5deg b=15deg+-5deg c=30deg+-5deg
----------
aa=1550r/min bb=1000r/min
----------
a=10deg+-5deg b=15deg+-5deg c=30deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(130deg)
----------
aa=16deg
----------
a=(130deg)
Information:
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 "PS5598" 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
April 30, 2000Problem
A fatigue crack in the nozzle adapter may cause high pressure fuel leaks. Customers will complain of engine misfiring/skipping and fuel leaking from nozzle due to a crack where fuel line is attached.
Affected Product
Model & Identification Number
D250E (5TN975-1839)
D300E (7FN485-1045)
D25D (1HK670-0743)
D30D (3AJ410-0440)
CH65C (2ZJ2400-2537)
970F (7SK800-1113)
615C (2XG1390-1745 9XG850-1210 )
Parts Needed
6 - 0R8782 NOZZLE AS-DIAction Required
If the fuel nozzle adapter cracks on an engine equipped with part number 100-7563 Nozzles in the affected serial number range, replace entire set of 100-7563 Nozzles with 0R8782 Nozzles.
Service Claim Allowances
This is a 2.5-hour job.
Parts Disposition
U.S. and Canadian Dealers
Return all 0R-8782 Nozzles that are replaced to:
Caterpillar Inc.
Service Claims Room
Attention: Howard Jenkel
8201 N. University
Peoria, IL 61615
All other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Termination Date
April 30, 2000Problem
A fatigue crack in the nozzle adapter may cause high pressure fuel leaks. Customers will complain of engine misfiring/skipping and fuel leaking from nozzle due to a crack where fuel line is attached.
Affected Product
Model & Identification Number
D250E (5TN975-1839)
D300E (7FN485-1045)
D25D (1HK670-0743)
D30D (3AJ410-0440)
CH65C (2ZJ2400-2537)
970F (7SK800-1113)
615C (2XG1390-1745 9XG850-1210 )
Parts Needed
6 - 0R8782 NOZZLE AS-DIAction Required
If the fuel nozzle adapter cracks on an engine equipped with part number 100-7563 Nozzles in the affected serial number range, replace entire set of 100-7563 Nozzles with 0R8782 Nozzles.
Service Claim Allowances
This is a 2.5-hour job.
Parts Disposition
U.S. and Canadian Dealers
Return all 0R-8782 Nozzles that are replaced to:
Caterpillar Inc.
Service Claims Room
Attention: Howard Jenkel
8201 N. University
Peoria, IL 61615
All other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.