Information injection-pump assembly
ZEXEL
101602-9700
1016029700
YANMAR
12765651010
12765651010
Rating:
Service parts 101602-9700 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
101602-9700
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-6653
as _
Cross reference number
ZEXEL
101602-9700
1016029700
YANMAR
12765651010
12765651010
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
3.8
3.75
3.85
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
11.6
Pump speed
r/min
900
900
900
Each cylinder's injection qty
mm3/st.
72
70.6
73.4
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.2+-0.5
Pump speed
r/min
300
300
300
Each cylinder's injection qty
mm3/st.
10
9
11
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT: RAL
(4)Rack difference between N = N1 and N = N2
(5)Idle sub spring setting: L1.
----------
K=15 RAL=17.5+0.2mm N1=800r/min N2=400r/min L1=8.1-0.5mm
----------
----------
K=15 RAL=17.5+0.2mm N1=800r/min N2=400r/min L1=8.1-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(17deg)+-5deg b=(36deg)+-5deg
----------
----------
a=(17deg)+-5deg b=(36deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=20deg+-5deg b=53deg+-5deg
----------
----------
a=20deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
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.
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 "PS8088" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the January 25, 1994 (Revised December 1994) Service Letter. Changes have been made to the Parts Stock Action.
Termination Date
January 31, 1996Problem
The fuel nozzles used on certain 3208 Engines may crack at the braze joint.
Affected Product
Model & Identification Number
3208 ( 30A5540-5956 (Arrangements 9Y8574, 9Y8575, 1228675, 1228676, 1228679, 1228680); 62W74820-80012 (Arrangements 0R0776, 0R0975, 0R0976, 0R2818, 0R2819, 0R2875, 0R3231); 5YF1531-2058 (Arrangements 4P2649, 4P3027, 9Y2229, 9Y3136, 1042666, 1061496, 1077956, 1077957); 01Z26425-28100 (Arrangements 2W1320, 2W1325, 7W7500, 7W9150, 1013714, 1176582); 03Z11912-13004 (Arrangements 4P1724, 1067075, 1108885, 1168163, 1168164, 1168165, 1214692); 51Z81870-82239 (Arrangements 4P0921, 4P0922, 111364); 93Z8798-11332 (Arrangement 0R1098); 99R1533-1541 (Arrangement 5R6639); 79V24858 (Arrangement 1W0331))
Parts Needed
1 - 0R2503 Nozzle Assembly (Reman Equivalent of 1W5829)*1 - 0R2821 Nozzle Assembly (Reman Equivalent of 7W3710)*1 - 0R3284 Nozzle Assembly (Reman Equivalent of 4W8483)*1 - 1153354 Nozzle Assembly (No Reman Equivalent)**Use as requiredAction Required
Parts Stock
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies from Parts Stock with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4. Date codes are located on the nozzle assembly as shown below:
Location of Date CodeAffected Product
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4 from the engine and replace with new nozzle assemblies or the remanufactured equivalent nozzle assemblies.
Service Claim Allowances
Parts Stock
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Affected Product
Industrial and Marine Engines Up to 6-hours labor may be claimed.
Truck Engines Claim labor hours in accordance with TRG book.
Parts Disposition
U.S. and Canadian Dealers
Return all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn:Howard Jenkel
Service Claims Room
8201 N. University
Peoria, IL 61615
For remanufactured nozzle assemblies 0R2503, 0R2821, and 0R3284, include a copy of the "Core Credit Request Packing List".
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
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 "PS8088" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the January 25, 1994 (Revised December 1994) Service Letter. Changes have been made to the Parts Stock Action.
Termination Date
January 31, 1996Problem
The fuel nozzles used on certain 3208 Engines may crack at the braze joint.
Affected Product
Model & Identification Number
3208 ( 30A5540-5956 (Arrangements 9Y8574, 9Y8575, 1228675, 1228676, 1228679, 1228680); 62W74820-80012 (Arrangements 0R0776, 0R0975, 0R0976, 0R2818, 0R2819, 0R2875, 0R3231); 5YF1531-2058 (Arrangements 4P2649, 4P3027, 9Y2229, 9Y3136, 1042666, 1061496, 1077956, 1077957); 01Z26425-28100 (Arrangements 2W1320, 2W1325, 7W7500, 7W9150, 1013714, 1176582); 03Z11912-13004 (Arrangements 4P1724, 1067075, 1108885, 1168163, 1168164, 1168165, 1214692); 51Z81870-82239 (Arrangements 4P0921, 4P0922, 111364); 93Z8798-11332 (Arrangement 0R1098); 99R1533-1541 (Arrangement 5R6639); 79V24858 (Arrangement 1W0331))
Parts Needed
1 - 0R2503 Nozzle Assembly (Reman Equivalent of 1W5829)*1 - 0R2821 Nozzle Assembly (Reman Equivalent of 7W3710)*1 - 0R3284 Nozzle Assembly (Reman Equivalent of 4W8483)*1 - 1153354 Nozzle Assembly (No Reman Equivalent)**Use as requiredAction Required
Parts Stock
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies from Parts Stock with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4. Date codes are located on the nozzle assembly as shown below:
Location of Date CodeAffected Product
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4 from the engine and replace with new nozzle assemblies or the remanufactured equivalent nozzle assemblies.
Service Claim Allowances
Parts Stock
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Affected Product
Industrial and Marine Engines Up to 6-hours labor may be claimed.
Truck Engines Claim labor hours in accordance with TRG book.
Parts Disposition
U.S. and Canadian Dealers
Return all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn:Howard Jenkel
Service Claims Room
8201 N. University
Peoria, IL 61615
For remanufactured nozzle assemblies 0R2503, 0R2821, and 0R3284, include a copy of the "Core Credit Request Packing List".
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.