Information injection-pump assembly
ZEXEL
101602-9540
1016029540
Rating:
Cross reference number
ZEXEL
101602-9540
1016029540
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
2.95
3.05
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
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
51.4
49.8
53
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8.2
6.4
10
Max. variation between cylinders
%
0
-12
12
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
----------
K=20 RAL=12+0.2mm
----------
----------
K=20 RAL=12+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=24deg+-5deg b=26deg+-5deg
----------
----------
a=24deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
0000001501 GOV FULL LOAD ADJUSTMENT
Title1:Full load stopper adjustment
Title2:Governor set speed
LABEL1:Distinguishing
LABEL2:Pump speed (r/min)
LABEL3:Ave. injection quantity (mm3/st)
LABEL4:Max. var. bet. cyl.
LABEL5:Remarks
LABEL6:Distinguishing
LABEL7:Governor set speed (r/min)
LABEL8:Maximum no-load speed (r/min)
LABEL9:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)At high idle rack position L
----------
L=7.3mm
----------
a1=A a2=B a3=- a4=- a5=- a6=- r1=900r/min r2=900r/min r3=- r4=- r5=- r6=- Q1=54.7+-1.6mm3/st Q2=51.4+-1.6mm3/st Q3=- Q4=- Q5=- Q6=- c1=+-2% c2=+-2% c3=- c4=- c5=- c6=- a7=27 a8=26 a9=25 a10=24 a11=23 a12=22 a13=21 a14=20 a15=19 a16=18 a17=17 a18=16 a19=15 a20=14 r7=1350r/min r8=1300r/min r9=1250r/min r10=1200r/min r11=1150r/min r12=1100r/min r13=1050r/min r14=1000r/min r15=950r/min r16=900r/min r17=850r/min r18=800r/min r19=750r/min r20=700r/min R7=1450+-33r/min R8=1395+-32r/min R9=1340+-31r/min R10=1290+-30r/min R11=1235+-28r/min R12=1180+-27r/min R13=1130+-26r/min R14=1075+-25r/min R15=1020+-23r/min R16=965+-22r/min R17=915+-22r/min R18=860+-20r/min R19=805+-18r/min R20=750+-17r/min
----------
L=7.3mm
----------
a1=A a2=B a3=- a4=- a5=- a6=- r1=900r/min r2=900r/min r3=- r4=- r5=- r6=- Q1=54.7+-1.6mm3/st Q2=51.4+-1.6mm3/st Q3=- Q4=- Q5=- Q6=- c1=+-2% c2=+-2% c3=- c4=- c5=- c6=- a7=27 a8=26 a9=25 a10=24 a11=23 a12=22 a13=21 a14=20 a15=19 a16=18 a17=17 a18=16 a19=15 a20=14 r7=1350r/min r8=1300r/min r9=1250r/min r10=1200r/min r11=1150r/min r12=1100r/min r13=1050r/min r14=1000r/min r15=950r/min r16=900r/min r17=850r/min r18=800r/min r19=750r/min r20=700r/min R7=1450+-33r/min R8=1395+-32r/min R9=1340+-31r/min R10=1290+-30r/min R11=1235+-28r/min R12=1180+-27r/min R13=1130+-26r/min R14=1075+-25r/min R15=1020+-23r/min R16=965+-22r/min R17=915+-22r/min R18=860+-20r/min R19=805+-18r/min R20=750+-17r/min
Timing setting
(1)Pump vertical direction
(2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Caterpillar: Confidential Yellow
PSP FOR INSTALLATION OF NEW INTERNAL FUEL INJECTION LINES ON CERTAIN 992C LOADERS; 773B TRUCKS; D9L, 651E, 657E, 772B TRA CTORS - MAILED US AND CANADA, CACO, COSA, LIMITED BRAZIL
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.
PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF NEW INTERNAL FUEL INJECTION LINES ON CERTAIN 992C LOADERS; 773B TRUCKS; D9L, 651E, 657E, 772B TRACTORS, 1252, PS4094 U-116 A-52 C-112 B-10.1 O-84 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4094" as Part Number and "7755" as Group Number. Although products in the field are to be administered as described above, dealers should purge parts stock immediately. Termination Date
November 30, 1987
Problem
There have been some failures of the 2W8142 Line As. (internal fuel lines - under the valve cover) on the Affected Product. These failures have been cracks in the fuel lines which can result in poor engine performance and dilution of the engine oil with fuel. New fuel lines are now used in production.
Affected Product
Model Identification Number D9L 14Y2971, 3023-3039, 3041-3046, 3048-3139, 3141-3569, 3571-3609, 3611-3661, 3663-3675, 3677-3686, 3688-3697, 3699-3701, 3705-3707, 3709-3730, 3732-3775, 3777-3960, 3962-3966, 3974-3976, 3983 651E 89Z109 - 113, 116-142 657E 90Z127 - 133, 135-173 91Z217 - 282 772B 64W172, 173 773B 63W1443, 1462, 1464-1489, 1491-1827, 1831, 1836, 1842, 1843 992C 49Z622, 623, 626-628, 630, 634, 636, 638, 639, 641-643, 645-649, 651-765, 767-771, 773-819, 821-939, 944
Parts Needed
12 - 7C5570 Line As. Use as needed. If one or more 7C5570 Line As. have already been installed, they should not be replaced. Only replace the 2W8142 Line Assemblies.
Action Required
Parts Stock Remove all 2W8142 Line Assemblies from parts stock. Affected Product All 2W8142 Line Assemblies on an engine should be replaced at the same time. Install the new parts according to the procedures in the appropriate Service Manuals. WARRANTY ALLOWANCES Parts Stock Submit one claim for all 2W8142 Line Assemblies that are removed from parts stock. (SEE ILLUSTRATION)
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
PSP FOR INSTALLATION OF NEW INTERNAL FUEL INJECTION LINES ON CERTAIN 992C LOADERS; 773B TRUCKS; D9L, 651E, 657E, 772B TRA CTORS - MAILED US AND CANADA, CACO, COSA, LIMITED BRAZIL
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.
PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF NEW INTERNAL FUEL INJECTION LINES ON CERTAIN 992C LOADERS; 773B TRUCKS; D9L, 651E, 657E, 772B TRACTORS, 1252, PS4094 U-116 A-52 C-112 B-10.1 O-84 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4094" as Part Number and "7755" as Group Number. Although products in the field are to be administered as described above, dealers should purge parts stock immediately. Termination Date
November 30, 1987
Problem
There have been some failures of the 2W8142 Line As. (internal fuel lines - under the valve cover) on the Affected Product. These failures have been cracks in the fuel lines which can result in poor engine performance and dilution of the engine oil with fuel. New fuel lines are now used in production.
Affected Product
Model Identification Number D9L 14Y2971, 3023-3039, 3041-3046, 3048-3139, 3141-3569, 3571-3609, 3611-3661, 3663-3675, 3677-3686, 3688-3697, 3699-3701, 3705-3707, 3709-3730, 3732-3775, 3777-3960, 3962-3966, 3974-3976, 3983 651E 89Z109 - 113, 116-142 657E 90Z127 - 133, 135-173 91Z217 - 282 772B 64W172, 173 773B 63W1443, 1462, 1464-1489, 1491-1827, 1831, 1836, 1842, 1843 992C 49Z622, 623, 626-628, 630, 634, 636, 638, 639, 641-643, 645-649, 651-765, 767-771, 773-819, 821-939, 944
Parts Needed
12 - 7C5570 Line As. Use as needed. If one or more 7C5570 Line As. have already been installed, they should not be replaced. Only replace the 2W8142 Line Assemblies.
Action Required
Parts Stock Remove all 2W8142 Line Assemblies from parts stock. Affected Product All 2W8142 Line Assemblies on an engine should be replaced at the same time. Install the new parts according to the procedures in the appropriate Service Manuals. WARRANTY ALLOWANCES Parts Stock Submit one claim for all 2W8142 Line Assemblies that are removed from parts stock. (SEE ILLUSTRATION)
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.