101609-9240 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016099240

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-9240 1016099240

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Cross reference number

ZEXEL 101609-9240 1016099240

Zexel num

Bosch num

Firm num

Name

101609-9240

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 105780-8310

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2240

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8120

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.5 3.47 3.53

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 13

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 58.5 56.5 60.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 13 11.2 14.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 58.5 57.5 59.5

Basic *

Fixing the lever *

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.
----------
T1=P33
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=39mm
----------
a=35.5deg+-3deg b=14deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=22mm
----------
a=40deg+-5deg b=20deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(20deg)

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.