Information injection-pump assembly
ZEXEL
101601-9830
1016019830
Rating:
Service parts 101601-9830 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5519
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-9830
1016019830
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
1-4-2-6-
3-5
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 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.8
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
58.9
57.9
59.9
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
R1(10)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
80.6
79.6
81.6
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8.3
6.5
10.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
80
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
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.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Damper spring setting: DL
(2)Excess fuel setting for starting: SXL
----------
DL=7-0.2mm SXL=R1+0.2mm
----------
----------
DL=7-0.2mm SXL=R1+0.2mm
----------
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
----------
aa=120mm
----------
a=19.5deg+-3deg b=12deg+-5deg
----------
aa=120mm
----------
a=19.5deg+-3deg b=12deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
PROBLEM
The Diesel Particulate Filter core may fail on certain C3.4B Industrial Engines. The failures may result in loss of power and a blocked Diesel Particulate Filter.
AFFECTED PRODUCT
Model Identification Number
C3.4B CJG01859-01865, 1867, 1869-1870, 1901-1910, 1994, 2268, 2272, 2323-2324, 2364-2365, 2367-2374, 2376-2377, 2414, 2430-2439, 2441-2446, 2454-2456, 2458-2460, 2462-2463, 2482, 2529, 4411-4414, 4453-4465, 4999-5025, 5048-5050, 5069-5088, 5090-5095
CNW00578-00579, 581-587, 666, 668-674, 677, 680, 684, 708, 730-738, 740-744, 746, 748-750
PARTS NEEDED
Qty
Part Number Description
1 20R3615 KIT-FILTER (After Failure Only)
1 3793061 SEAL (After Failure Only)
1 3793064 SEAL-O-RING (After Failure Only)
1 3879343 CLIP (After Failure Only)
1 4732321 ENGINE SOFTWARE
1 4813598 FILTER AS (After Failure Only)
1 GND_WIRE_KIT Regen Interlock GND Wire Kit (See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 26% 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
Before Failure:
1 - Update Engine Software, refer to Troubleshooting ? ECM Software ? Install, ensure to follow the steps to save the Engine Configuration data.
2 - Apply Carlson Service Number 14CP-013 - Regeneration Interlock Ground Wire Kit, contact a Carlson Paving Products Dealer for Kit Part Number 14CP-013.
After Failure:
1 - Refer to Steps 1 and 2 of the Before Failure actions.
2 - Service CCB Filter and replace with new filter, refer to Operation and Maintenance Manual ? Engine Crankcase Breather element ? Replace.
3 - Remove Diesel Particulate Filter, Refer to Disassembly and Assembly - Diesel Particulate Filter - Remove - wall Flow Diesel Particulate Filter.
4 - Move the Diesel Particulate Filter Assembly to a suitable work surface.
5 - Refer to Specifications - Diesel Particulate Filter (Wall Flow Diesel Particulate Filter(DPF)), remove V Band Clamps (1) and (4), carefully split assembly and remove DPF Canister element.
6 - Using new DPF Kit Filter, reassemble the Diesel Particulate Filter Assembly noting the alignment marks previously made in Step 3, refer to Specifications - Diesel Particulate Filter (Wall Flow Diesel Particulate Filter(DPF)).
7 - Reinstall the Diesel Particulate Filter assembly, Refer to Disassembly and Assembly - Diesel Particulate Filter - Install - wall Flow Diesel Particulate Filter.
8 - As the DPF has been replaced, ensure the ?DPF Replacement Reset? procedure is performed using CAT ET, refer to Troubleshooting - Service Tool Features - Components Replacement Resets.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.5-hour job
Note an additional 4.5 hours is allowed for After Failure.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.