101603-7306 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037306

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7306 1016037306

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Service parts 101603-7306 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4921

3. GOVERNOR 105931-6564

4. SUPPLY PUMP 105220-5930

5. AUTOM. ADVANCE MECHANIS 105644-0440

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5095

11. Nozzle and Holder 1-15300-266-4

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1111

15. NOZZLE SET

Include in #1:

101481-0151 as _

101603-7306 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7306 1016037306

Zexel num

Bosch num

Firm num

Name

101603-7306

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 13.2

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 95.7 94.1 97.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 95.7 94.7 96.7

Basic *

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 96.7 93.5 99.9

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 55)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 77 73.8 80.2

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.85

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 61.9 58.7 65.1

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 125

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-0.85

Boost pressure kPa 3.3 3.3 6

Boost pressure mmHg 25 25 45

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 55)

Boost pressure kPa 14.7 14.7 14.7

Boost pressure mmHg 110 110 110

Timer adjustment

Pump speed r/min (1170)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=F36 BCL=0.85+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=44mm
----------
a=43deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

0000001701 LEVER

1. Accelerator lever adjustment (1)Set the speed lever (A) at the idle point H. (2)Set the control lever where the accelerator lever (B) contacts the speed lever hook (C). (3)The gap between the accelerator lever (B) and the stopper bolt (D) must be L1.
----------
L1=1+0.5mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(60deg)

Information:

PARTS NEEDED
Qty
Part Number Description
*******Group 1*******
6 2530618 INJECTOR GP-FUEL
1 3085693 SOFTWARE GP-ELEK
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*******Group 2*******
1 3085693 SOFTWARE GP-ELEK
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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
Group 1 Engines:
Remove the existing 291-5911 injectors and replace with a new set of 253-0618 injectors. Once this is complete, flash the Engine ECM with the 308-5693 software file.
Group 2 Engines:
Flash the Engine Ecm with the 308-5693 software file.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
100% 100% 0% 0% 0% 0%
This is a 3.0-hour job for Group 1
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ENGINE ELECTRONIC CONTROL MODULE (ECM) SOFTWARE AND POSSIBLY THE INJECTORS ON CERTAIN C18 INDUSTRIAL ENGINES
MODELS INVOLVED - C18 Industrial Engines
Dear Caterpillar Product Owner:
The Engine software and possibly the injectors need to be replaced on the C18 Industrial Engines listed below. The existing injectors do not work properly with the current software. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 28Feb2008 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 28Feb2008 Service Letter