Information injection-pump assembly
ZEXEL
101631-9610
1016319610
Rating:
Service parts 101631-9610 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-20053
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101631-9610
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-3080
as _
Cross reference number
ZEXEL
101631-9610
1016319610
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
2.15
2.1
2.2
Rack position
R=10.7
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.2
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
32.5
31.5
33.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.7
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
36.6
35
38.2
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
7.5
6.5
8.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.7
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
1.7
1.2
2.2
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.6
3.1
4.1
Timer adjustment_05
Pump speed
r/min
1900
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
P:Negative pressure
(1)Pneumatic governor
(2)Mechanical governor
(3)Acting negative pressure: P1
(4)RACK LIMIT: RAL
(5)Beginning of idle sub spring operation: L1
(6)Injection quantity Q = Q1 or less
----------
RAL=16mm L1=8+0.3mm Q1=3mm3/st
----------
----------
RAL=16mm L1=8+0.3mm Q1=3mm3/st
----------
Speed control lever angle
N:Normal
B:When boosted
S:Stop
(1)Rack position = aa
----------
aa=(1.8)mm
----------
a=20.5deg+-3deg b=8deg+-5deg c=0.5deg+-5deg
----------
aa=(1.8)mm
----------
a=20.5deg+-3deg b=8deg+-5deg c=0.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(130deg)
----------
----------
a=(130deg)
Information:
Before completing the attached Rework Procedure, review the safety actions in the Operation and Maintenance Manual for safety information and safe working practices before starting the rework.
If the head gasket has failed replace the head gasket and the fuel injection pump.
If the head gasket has not failed replace the fuel injection pump only.
The 483-2326 Fuel Injection Pump has revised injection timing to reduce the peak cylinder pressure in the engine. It is essential that the pump is installed as per the Disassembly and Assembly, "Fuel Injection Pump - Install - Delphi DP210" to achieve the desired fuel injection timing.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.5-hour job
For After failure, and additional 13.8 hours is allowed. A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
If the head gasket has failed follow the rework procedure for both head gasket replacement and for fuel injection pump replacement
If the head gasket has not failed follow the rework procedure for fuel injection pump replacement only.
Head gasket replacement:
Confirm the head gasket has failed through removal of the cylinder head and visual inspection of the gasket. Remove cylinder head ? refer to Disassembly and Assembly, "Cylinder Head - Remove". Confirm head gasket has failed through visual inspection, as per the images shown in Image 1.1.1.
Clean the cylinder head face and the cylinder block face to remove any deposits on the gasket sealing surface using an appropriate cleaner. Do not use abrasive materials to remove the deposits during the cleaning process to ensure that the correct surface flatness is maintained.
Inspect cylinder head for flatness and distortion. Refer to Image 1.1.2 for surface finish. Refer to System Operation Testing and Adjusting, "Cylinder Head ? Inspect" for more information. Resurface the cylinder head if required as per Testing and Adjusting, "Cylinder Head ? Inspect".
Inspect cylinder block for surface finish on the top deck of the cylinder block. Refer to Image 1.1.2 for surface finish. If the cylinder block is within specifications, install a new 258-4946 Cylinder Head Gasket. If the block is not within specification, refer to Reuse And Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks" for more information.
Note: A 369-3705 Cylinder Head Gasket may be required, depending on reuse and salvage guidelines.
Follow Disassembly and Assembly, "Cylinder Head ? Install" with a new gasket as per above information.
Fuel injection pump replacement:
Follow Disassembly and Assembly, "Fuel Injection Pump - Remove - Delphi DP210". Do not reuse the fuel pump. Record removed fuel pump serial number in claim story. The fuel pump serial number is in the format "12345ABC".
Install the new