Information injection-pump assembly
ZEXEL
101601-9982
1016019982
Rating:
Cross reference number
ZEXEL
101601-9982
1016019982
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
4.6
4.55
4.65
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
B
Rack position
10.6
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
86.6
85.6
87.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
10
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
67.1
64.1
70.1
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
8.4+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
8
6.5
9.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
100
100
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
4
3.5
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)Excess fuel setting for starting: SXL
(4)Damper spring setting: DL
(5)Microswitch adjustment unnecessary.
----------
RT=1 TH=2.4mm SXL=10.7+0.2mm DL=7.5-0.2mm
----------
----------
RT=1 TH=2.4mm SXL=10.7+0.2mm DL=7.5-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=6deg+-5deg
----------
----------
a=6deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=24deg+-3deg
----------
----------
a=10deg+-5deg b=24deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=71deg+-5deg
----------
----------
a=20deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position for the No. 6 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
TERMINATION DATE
31Oct2022
PROBLEM
The existing 6I-2358 Fuel Injector Pump can Leak out of one or both bushings on certain 3412C Generator Sets. If the existing fuel injector pump leaks oil it will run down the side of the engine.
AFFECTED PRODUCT
Model Identification Number
3412C DK600101, 579, 703, 816, 818, 820, 822-970, 972-1011, 1013-1022, 1024-1276, 1278-1286, 1372-1374, 1376-1473, 1475-1551, 1553, 1555-1559, 1561
PARTS NEEDED
Qty
Part Number Description
2 1S0004 SEAL-O-RING
1 2H3931 SEAL-O RING
1 4P7886 GASKET
1 6I0972 GASKET
1 8T9527 SEAL-O-RING
1 9Y6042 GASKET-OIL PUMP
1 9Y8058 GASKET
1 2109246 SEAL-O-RING
1 4202031 KIT-GASKET (F)
1 BULK_COOLANT ELC COOLANT - see OMM (Qty As Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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
Refer to Special Instruction, M0123519.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-4000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-7000 hrs,
13-24 mo 50.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 6.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.