Information injection-pump assembly
ZEXEL
101492-9072
1014929072
Rating:
Service parts 101492-9072 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-T9303
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-9072
1014929072
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
131424-6120
Overflow valve opening pressure
kPa
191
157
225
Overflow valve opening pressure
kgf/cm2
1.95
1.6
2.3
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
A
Rack position
8.8
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
35.7
34.7
36.7
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.1
Pump speed
r/min
825
825
825
Average injection quantity
mm3/st.
37.3
33.3
41.3
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
375
375
375
Average injection quantity
mm3/st.
13
11
15
Max. variation between cylinders
%
0
-10
10
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_04
Adjusting point
D
Rack position
13.9+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
75
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Set idle sub-spring
(4)Main spring setting
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=5deg+-5deg b=15deg+-5deg c=32deg+-3deg
----------
----------
a=5deg+-5deg b=15deg+-5deg c=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=10.5deg+-5deg b=53deg+-5deg
----------
----------
a=10.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole (position of gear mark 'N') at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
AFFECTED PRODUCT
Model Identification Number
994K MM900301-00322
MRK00201-00204, 312-333
SMX00201-00209
PARTS NEEDED
Qty
Part Number Description
2 4538963 INJECTOR AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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
The existing standard grease injectors will need to be replaced with new 453-8963 XL Injector Assemblies for the both left-hand and right-hand K-pins. Refer to Image1.
Refer to the attached Rework Procedure.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-15000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to the following Rework Procedure in order to install two new 453-8963 XL Injector Assemblies.
Refer to Image1.1.1 for the location of the injector bank.
1. Remove cover (A). Refer to Image1.1.2.
Image1.1.1
Image1.1.2
2. Remove existing injectors (C). Refer to Image1.2.1.
Image1.2.1
3. In order to remove the existing injector, loosen lower bolt (D) from the injector bank until half of the injector is free. Refer to Image1.3.1.
4. Remove the existing grease zerks, grease zerk caps, and adapters and reinstall on the new 453-8963 XL Injector Assemblies.
Image1.3.1
5. Install new 453-8963 XL Injector Assemblies (1).
6. Purge 453-8963 XL Injector Assemblies (1) with grease.
7. Adjust to full output (20 turns).
8. Reinstall cover (A).
Image1.4.1