Information injection-pump assembly
ZEXEL
101491-9042
1014919042
Rating:
Cross reference number
ZEXEL
101491-9042
1014919042
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 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
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
3.4
3.35
3.45
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
-
Rack position
11.28+-0
.02
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
57.7
57.2
58.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.3+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9
7
11
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
11.28+-0
.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
57.7
57.2
58.2
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
11.55+-0
.5
Pump speed
r/min
1700
1700
1700
Average injection quantity
mm3/st.
70
68
72
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
11.39+-0
.5
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
42.9
40.9
44.9
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1350+-25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1700
Advance angle
deg.
3.5
3.2
3.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: R1, speed N1
(3)Torque cam set point
----------
T1=A19 R1=+-0.02mm N1=+-3r/min
----------
----------
T1=A19 R1=+-0.02mm N1=+-3r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=20deg+-5deg b=41deg+-3deg
----------
----------
a=20deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=40deg+-5deg b=40deg+-5deg
----------
----------
a=40deg+-5deg b=40deg+-5deg
0000001501 GOV RACK POSITION CONFIRM
Confirm the governor adjustment rack position.
Standard point A
Set the torque cam B.
(C) Confirmation
(D) Remarks
(N): Speed of the pump
(R) Rack position (mm)
----------
----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.28+-0.02mm Rb=11.39+-0.02mm Rc=11.34+-0.1mm Rd=11.55+-0.05mm Re=11.46+-0.05mm Rf=11.53+-0.05mm
----------
----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.28+-0.02mm Rb=11.39+-0.02mm Rc=11.34+-0.1mm Rd=11.55+-0.05mm Re=11.46+-0.05mm Rf=11.53+-0.05mm
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(130deg)
----------
----------
a=(130deg)
Information:
Caterpillar: Confidential Yellow
PRIORITY - FUEL INJECTOR TIMING NEEDS TO BE RESET TO NEW DIMENSION ON CERTAIN 785 TRUCKS & 3512 ENGINES - MAILED US, CAN ADA, BRAZIL, LIMITED COFA, COSA
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.
U-128 AU-78.1 B-8 O-72.1 PRIORITY 1290 PI3345 COMPLETION DATE Termination Date
February 28, 1989 August 31, 1989
Problem
The dimension for fuel injector timing has been changed. The new dimension will help increase the service life of the pistons.
Affected Product
Model Identification Number 785 8GB127, 173, 174, 197, 208, 209, 221, 223, 224, 228-230, 232-236, 241-243, 244-254, 257, 265, 267, 268, 270 3512 96Z381, 391
Parts Needed
1 - 4W5140 Plate
Action Required
Change the fuel injector timing to 87.3 mm using the procedure in the Service Manual. Stamp the information which follows on the new information plate and install the plate. AR NO. 1W5220 PERF SPEC 0T5183 MAX ALT 2250 M FULL LOAD STATIC FUEL 8.80 mm FULL TORQ. STATIC FUEL 11.0 mm POWER 1382 hp 1031 kw A/F RATIO DYNAMIC 2.00 mm BARE ENG. HIGH IDLE RPM 1950 FULL LOAD RPM 1750 FUEL TIMING 87.30 mm
Service Claim Allowances
Caterpillar Dealer Suggested Customer Suggested Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. (D/N) (Sell) (C/L) (Sell) 100%
PRIORITY - FUEL INJECTOR TIMING NEEDS TO BE RESET TO NEW DIMENSION ON CERTAIN 785 TRUCKS & 3512 ENGINES - MAILED US, CAN ADA, BRAZIL, LIMITED COFA, COSA
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.
U-128 AU-78.1 B-8 O-72.1 PRIORITY 1290 PI3345 COMPLETION DATE Termination Date
February 28, 1989 August 31, 1989
Problem
The dimension for fuel injector timing has been changed. The new dimension will help increase the service life of the pistons.
Affected Product
Model Identification Number 785 8GB127, 173, 174, 197, 208, 209, 221, 223, 224, 228-230, 232-236, 241-243, 244-254, 257, 265, 267, 268, 270 3512 96Z381, 391
Parts Needed
1 - 4W5140 Plate
Action Required
Change the fuel injector timing to 87.3 mm using the procedure in the Service Manual. Stamp the information which follows on the new information plate and install the plate. AR NO. 1W5220 PERF SPEC 0T5183 MAX ALT 2250 M FULL LOAD STATIC FUEL 8.80 mm FULL TORQ. STATIC FUEL 11.0 mm POWER 1382 hp 1031 kw A/F RATIO DYNAMIC 2.00 mm BARE ENG. HIGH IDLE RPM 1950 FULL LOAD RPM 1750 FUEL TIMING 87.30 mm
Service Claim Allowances
Caterpillar Dealer Suggested Customer Suggested Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. (D/N) (Sell) (C/L) (Sell) 100%