101491-9171 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919171


 

Information injection-pump assembly

ZEXEL 101491-9171 1014919171
101491-9171 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101491-9171 1014919171


Zexel num
Bosch num
Firm num
Name
101491-9171 
101491-9172 
 
   
INJECTION-PUMP ASSEMBLY
4102Q *

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
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   3.4 3.35 3.45
Rack position
Point A
  R=A
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   -
Rack position   10.2
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   51 49.4 52.6
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   -
Rack position   9.8+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   9.5 8 11
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.2)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   51 50 52
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   C
Rack position   10.3+-0. 5
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   40 38.4 41.6
Fixing the lever   *
Timer adjustment
Pump speed r/min   1250--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   2 1.5 2.5
Timer adjustment_04
Pump speed r/min   1750
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101491-9171
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1
----------
T1=55
----------

Speed control lever angle

Test data 101491-9171
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=5.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101491-9171
N:Pump normal S:Stop the pump.
----------

----------
a=45deg+-5deg b=40deg+-5deg

Timing setting

Test data 101491-9171
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(90deg)




Information:


15Jun2015
(Revised 08Sep2015)
U-312
A-215
D-253
O-261
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 10R4761 AND 10R4763 REMAN INJECTORS FROM DEALER PARTS STOCK
7750 PI70569
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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.
This Revised Service Letter replaces the 15Jun2015 (Revised 12Aug2015) Service Letter. Changes have been made to Action Required and Service Claim Allowance. A request for photographs to be submitted with the claims story has been added.
TERMINATION DATE
30Sep2015
PROBLEM
Certain reman fuel injectors were mislabeled with an incorrect part number.
ACTION REQUIRED
Inspect all 10R4761 and 10R4763 Reman Fuel Injectors in dealer parts stock.
If an injector has a 12-character serial number listed in the table in Image 1, remove the part from dealer parts stock. Refer to the Parts Disposition. Include the Injector Serial Number in the Claim Story. Also, attach a photograph of the injector serial number with the claim story.
If an injector does not have a 12-character serial number listed in the table in Image 1, mark the package to indicate that the part has been inspected according to this program and return the part to dealer parts stock.
Image 2 identifies Reman Hydraulic Electronic Unit Injector (HEUI) product markings.
(1) 7-character Part Number
(2) 12-character Serial Number
(3) 4-digit Confirmation Code
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock. Include the Injector Serial Number(s) in the Claim Story. Also, attach a photograph of the injector serial number with the claim story.
PARTS DISPOSITION
NACD:
Hold all 10R4761 and 10R4763 Reman Fuel Injectors removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
EAME, LACD, and APD:
Hold all 10R4761 and 10R4763 Reman Fuel Injectors removed from dealer parts stock for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
Contact Runge_Mark_H at Reman Product Support for a Parts Return Request (PRR).
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

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