Information injection-pump assembly
ZEXEL
101491-9221
1014919221
MAZDA
SL4613800
sl4613800
Rating:
Service parts 101491-9221 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
SL01 13 640
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-9221
1014919221
MAZDA
SL4613800
sl4613800
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
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
16.3+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
91
81
96
Fixing the lever
*
Rack limit
*
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)RACK LIMIT
(4)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.
(1)Engine normal
(2)Engine stop
(3)Set the speed to aa using the idle lever and then confirm non-injection.
(4)(Actual measurement)
(5)Set the normal set bolt.
----------
aa=300r/min
----------
a=40deg+-5deg b=23deg+-5deg c=(15deg)+-5deg
----------
aa=300r/min
----------
a=40deg+-5deg b=23deg+-5deg c=(15deg)+-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
0000001601 LEVER
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
Stop lever's normal position setting method
1. (1) Push in the set bolt (A) until the rack starts to move.
(2)Return the bolt N1 turns from that position and set.
2. Rack with limiter
(1)Return the bolt N1 turns from the rack limit position and set.
----------
N1=1.5
----------
----------
N1=1.5
----------
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:
04Feb2016
U-58
A-46
D-55
O-52
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 398-1498 AND 463-1678 FUEL INJECTION PUMPS FROM DEALER PARTS STOCK
7750 PI70604
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.
TERMINATION DATE
31May2016
PROBLEM
The existing 398-1498 and 463-1678 Fuel Injection Pumps can fail. Fuel Injection Pumps up to and inclusive of component serial number 06369GJG, are suspect.
ACTION REQUIRED
Inspect all 398-1498 and 463-1678 Fuel Injection Pumps in dealer parts stock. Review the component serial number on each 398-1498 and 463-1678 Fuel Injection Pump. The Fuel Injection Pump component serial number can be located on the Fuel Injection Pump data plate, affixed to the side of the Fuel Injection Pump body.
The Fuel Injection Pump component serial number is alphanumeric, Refer to Image 1 for explanation on component serial number translation. In the given example the date code would translate to the following - 6369th pump built in July 2015.
NOTE - The build facility is not applicable in determining if the Fuel Injection Pump is suspect or not.
Refer to Image 2 for the build month and build year translation table.
Please action according to the following build month and build year color code -
Red = Remove from dealer part stock
Orange = Check Fuel Injection Pump Serial Number (06369 and below = Remove from dealer part stock / 06370 and Up = Return to dealer part stock).
Green = OK, Return to dealer part stock.
- If the Fuel Injection Pump is removed from dealer parts stock. Refer to the Service Claim Allowances and Parts Disposition.
- If the Fuel Injection Pump is returned to dealer parts stock, mark the box as inspected.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all Fuel Injection Pumps removed from dealer parts stock. Include the date code (e.g. 06369GJG) in the claim story for each Fuel Injection Pump removed from dealer parts stock.
PARTS DISPOSITION
NACD:
Hold all 398-1498 and 463-1678 Fuel Injection Pumps 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