Information injection-pump assembly
ZEXEL
101601-9890
1016019890
Rating:
Cross reference number
ZEXEL
101601-9890
1016019890
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.1
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
57
55
59
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.8
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
56
52
60
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.7+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
10.5
9
12
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
90
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
650--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
600
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Damper spring setting: DL
(4)Excess fuel setting for starting: SXL
----------
RT=1 TH=2.7mm DL=4.9-0.5mm SXL=8.1+0.2mm
----------
----------
RT=1 TH=2.7mm DL=4.9-0.5mm SXL=8.1+0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=17deg+-5deg
----------
----------
a=17deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10.5deg+-5deg b=25deg+-3deg
----------
----------
a=10.5deg+-5deg b=25deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=35deg+-5deg b=71deg+-5deg
----------
----------
a=35deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(170deg)
----------
----------
a=(170deg)
Information:
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.
This Program must be administered either before or after failure.In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46371" as the Part Numberand "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS 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
31Aug2021
PROBLEM
The existing fuel injectors may fail and create an overfueling event on certain 3512E Petroleum Engines.
AFFECTED PRODUCT
Model Identification Number
3512E SK500105-00106, 109-110, 115-116, 118-119
PARTS NEEDED
Qty
Part Number Description
12 20R7170 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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
It is recommended that the fuel injectors be replaced at an 8000 hour interval.
Refer to Disassembly and Assembly, KENR8163, "Fuel Injector - Remove and Install - Common Rail".
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-22000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.