101609-3480 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093480

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3480 1016093480

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Service parts 101609-3480 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5540

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101609-3480 as INJECTION-PUMP ASSEMBLY

Include in #2:

104058-3400 as _

Cross reference number

ZEXEL 101609-3480 1016093480

Zexel num

Bosch num

Firm num

Name

101609-3480

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 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 2.5 2.45 2.55

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 9.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 82.5 81.5 83.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 515 515 515

Average injection quantity mm3/st. 15 14 16

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 80

Fixing the lever *

Rack limit *

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)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (5)Rack difference between N = N1 and N = N2
----------
K=14 N1=1100r/min N2=675r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the center hole at R = aa
----------
aa=77mm
----------
a=18deg+-3deg b=32deg+-3deg c=33deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min

Information:

Caterpillar: Confidential Yellow
PSP FOR REPLACING UNIT INJECTOR RETURN SPRINGS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785, 789 TRUCKS; 3508, 3512, 351 6 ENGINES - PS4591 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, MARINE TEPS
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.
May 30, 1991 U-110 A-78 AU-66 E-69 O-82 TM-9 PRODUCT SUPPORT PROGRAM FOR REPLACING UNIT INJECTOR RETURN SPRINGS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785, AND 789 TRUCKS; AND 3508, 3512, AND 3516 ENGINES. 1290 PS4591 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 "PS4591" as Part Number, "7755" as Group Number, and "96" as Description Code. Although this Program is to be administered as described above on the Affected Product, parts stock should be reworked as soon as possible. Termination Date
May 31, 1992
Problem
The return springs for Type 2 unit injectors on certain D11N Tractors; 776B Tractors; 777B, 785, and 789 Trucks; and 3508, 3512, and 3516 Engines may fail in some applications. Type 2 injectors are described on