101609-3090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3090 1016093090

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Cross reference number

ZEXEL 101609-3090 1016093090

Zexel num

Bosch num

Firm num

Name

101609-3090

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 131424-1520

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

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

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 A

Rack position 10.2

Pump speed r/min 1190 1190 1190

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 50.7 50.7

Boost pressure mmHg 380 380

Injection quantity adjustment_02

Adjusting point B

Rack position 6.3+-0.5

Pump speed r/min 405 405 405

Average injection quantity mm3/st. 12.5 11.3 13.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 15+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 200 190 210

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 750 750 750

Rack position 10.05

Boost pressure kPa 21.3 18.6 24

Boost pressure mmHg 160 140 180

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 10.7

Boost pressure kPa 37.3 30.6 44

Boost pressure mmHg 280 230 330

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2 (6)Rack difference between N = N3 and N = N4
----------
K=13 RAL=15+0.2mm N1=1190r/min N2=800r/min N3=1190r/min N4=350r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=15deg+-5deg b=31deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Stopper bolt setting
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

TERMINATION DATE
31Jan2012
PROBLEM
The existing fuel injection pump can fail on certain CP-533E and CS-533E Vibratory Soil Compactors. If the existing fuel injection pump fails it can cause low power, poor starting, fuel leaks, and engine performance issues.
AFFECTED PRODUCT
Model Identification Number
CP-533E ASM00310-00311, 313, 316-380
BZG00466-01134
TLH00101-00147
CS-533E ASL03060, 3068, 3092, 3103, 3106, 3110, 3121, 3125-3126, 3130-3135, 3138-3872
BZE01120-02370
TBE00148-00237
TJL00100-01472, 1474-1628, 1630-1631, 1633-1637, 1639-1678
PARTS NEEDED
Qty
Part Number Description
1 2845000 PUMP GP-F INJ -B
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
Replace the failed fuel injection pump. Refer to the engine's Disassembly and Assembly, "Fuel Injection Pump - Remove and Install".
While carrying out "Fuel Injection Pump - Remove", please ensure that the fuel injection pump gear backlash is removed and the fuel injection pump locking bolt is tightened to a torque of 17 N.m (13 lb ft).
Fuel injection pumps that have not been locked correctly will have the claim rejected or debited.
After the new fuel injection pump has been installed, carry out checks for air in the fuel. Refer to the engine's Testing and Adjusting, "Air in Fuel - Test".
To ensure correct priming of the fuel system on first start-up, follow the procedure below.
1. Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly.
2. Turn the ignition key to the RUN position. Leave the ignition key in the RUN position for three minutes.
3. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
Note: If necessary, loosen the union nuts on the fuel injection lines at the connection with the fuel injector until fuel is evident. Stop cranking the engine. Tighten the union nuts to a torque of 30 N.m (22 lb ft).
4. Start the engine and run the engine at low idle for one minute.
5. Cycle the throttle lever from the low idle position to the high idle position three times. The cycle time for the throttle lever is one second to six seconds for one complete cycle.
6. Check for leaks in the fuel system.
DOCUMENTATION PROCEDURE
Please ensure that when submitting the claim the following documentation is provided. If the requested documentation is not provided, the claim may be rejected or debited.
1. Full details of the customer?s complaint and the symptoms witnessed.
2. Test work and checks carried out to diagnose that the fuel injection pump is the part causing failure.
3. Results from the Testing and Adjusting, "Air in Fuel - Test". Please include photos of any air seen in the SIMS entry.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
PARTS DISPOSITION
***** NACD *****
Hold all failed fuel injection pumps for a Parts Return Request (PRR). A PRR will be issued to you through the