101609-9271 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016099271 3436507031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-9271 1016099271

MITSUBISHI-HEAV 3436507031 3436507031

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Cross reference number

ZEXEL 101609-9271 1016099271

MITSUBISHI-HEAV 3436507031 3436507031

Zexel num

Bosch num

Firm num

Name

101609-9271

3436507031 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S6K-T K

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 131424-5720

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 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.65 3.75

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 A

Rack position 8.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 72 71 73

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 85.3 85.3

Boost pressure mmHg 640 640

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 8.95

Boost pressure kPa 33.3 30.6 36

Boost pressure mmHg 250 230 270

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 9.6

Boost pressure kPa 72 72 72

Boost pressure mmHg 540 540 540

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)Boost compensator stroke (4)Rack difference between N = N1 and N = N2
----------
K=14 N1=1100r/min N2=700r/min
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
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a=15deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (sealed at delivery) (3)Normal
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

0000001501 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
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Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)After adjusting the injection quantity, adjust at rack position bb.
----------
aa=6deg bb=8.6mm
----------
a=(60deg)

Information:

Caterpillar: Confidential Yellow
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PS0456 - US, CANADA, CACO, LTD COFA - REVISED 10/90
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.
(Revised October 1990) U-130 A-88 AU-86.1 1100, 1290 PS0456 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0456" as Part Number, "7755" as Group Number, and "96" as Description Code. If this Program is administered on E200B or EL200B Excavators, it is recommended that the June 22, 1990 Service Letter - PS4442 be done at the same time. This Revised Service Letter replaces the June 25, 1990 Service Letter. Changes have been made to add Affected Product. Termination Date
June 30, 1991
Problem
The fuel injector sleeves in the cylinder head of certain IT14B Integrated Toolcarriers; E110B, E120B, E200B, EL200B, 213B, 214B, 224B, E240B, and EL240B Excavators; 446 Backhoe Loaders; CB-434, CP-563, and CS-563 Compactors; AP-1050 Asphalt Pavers; and 3114 and 3116 Industrial and Generator Set Engines are subject to pitting and erosion due to fuel cavitation between the injector and the sleeve. The sleeves may pit or crack through, allowing fuel to contaminate the coolant. Coolant contaminated with fuel may also damage the radiator and coolant hoses.
Affected Product
Model Identification Number IT14B 3NJ1-42 E110B 8MF1-151 E120B 6JF1-212 E200B* 6KF1-439 6KG1-249 EL200B* 7DF1-986 213B 1EJ1-233, 236-245, 247, 248 214B