101502-9020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015029020

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101502-9020 1015029020

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Service parts 101502-9020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101050-8040

3. GOVERNOR 105419-0640

4. SUPPLY PUMP 105220-5480

5. AUTOM. ADVANCE MECHANIS 105621-0430

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7370

11. Nozzle and Holder 157-0753-001

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4990

14. NOZZLE 105015-7140

15. NOZZLE SET

Include in #1:

101502-9020 as INJECTION-PUMP ASSEMBLY

101692-3451 as _

Cross reference number

ZEXEL 101502-9020 1015029020

Zexel num

Bosch num

Firm num

Name

101502-9020

INJECTION-PUMP ASSEMBLY

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

Overflow valve 131424-4320

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-5-4- 2

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 72 71.5 72.5

Difference between angles 2
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 3
Cal 1-4 deg. 216 215.5 216.5

Difference between angles 4
Cyl.1-2 deg. 288 287.5 288.5

Injection quantity adjustment

Adjusting point A

Rack position 10.9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 83.8 82.3 85.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting (4)The torque control spring must does not have a set force. (5)Rack difference between N = N1 and N = N2
----------
K=14 N1=1200r/min N2=600r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(23deg)+-5deg b=(37deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(120deg)

Information:

21Apr2010
U-136
A-108
D-119
O-126
TT-9
TM-8
TA-5
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 248-1079, 250-1305, 250-1368, 266-4387, AND 280-0681 FUEL INJECTORS (FOR 3508C, 3512C, AND 3516C ENGINES) FROM DEALER PARTS STOCK
7750 PI70341
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
31Jul2010
PROBLEM
Certain 248-1079, 250-1305, 250-1368, 266-4387, and 280-0681 Fuel Injectors installed in certain 3512C and 3516C engine applications may experience internal body cracks. This condition may result in fuel to oil dilution.
ACTION REQUIRED
Refer to Image1 for Injector Part Numbers and Serial Number Range of affected parts. Refer to Image2 for example of part number (A) and injector serial number identification (B).
Inspect all injector part numbers listed in Image1 to identify if they are within the Serial Number range 1134640 - 1234085.
- If the injector part number listed in Image1 has a serial number that is included in the serial number range 1134640 - 1234085, remove the injector from dealer parts stock.
- If the injector part number listed in Image1 has a serial number that is NOT included in the serial number range 1134640 - 1234085, return the injector to the original packaging, mark the package to indicate the injector has been inspected according to this program (PI7#### / REBE6038), and return the injector to dealer parts stock.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
A Send-It-Back Parts Return Request will be generated when the claim is submitted with this program (PI7####) as the part causing failure.