Information injection-pump assembly
ZEXEL
101631-9773
1016319773
Rating:
Cross reference number
ZEXEL
101631-9773
1016319773
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
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
-
Rack position
12.2
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
32.1
31.1
33.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
11.7
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
36.1
34.5
37.7
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
8.6+-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
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
1.7
1.2
2.2
Timer adjustment_04
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
----------
P1=3.63+-0.2kPa(370+-20mmAg) RAL=14+-0.1mm L1=9+0.3mm Q1=3mm3/st
----------
----------
P1=3.63+-0.2kPa(370+-20mmAg) RAL=14+-0.1mm L1=9+0.3mm Q1=3mm3/st
----------
0000001101
N:Normal
B:When boosted
S:Stop
(1)Rack position = aa
----------
aa=0mm
----------
a=25deg+-3deg b=8deg+-5deg c=0.5deg+-5deg
----------
aa=0mm
----------
a=25deg+-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)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(130deg)
----------
aa=20deg
----------
a=(130deg)
Information:
PARTS NEEDED
Qty
Part Number Description
1 4609257 INJECTOR AS-DEF
1 5398400 SFWR GP-A1000
1 BULK_COOLANT COOLANT (MAX 1 GALLON)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
1. Remove the existing DEF injector assembly and replace with a new 460-9257 DEF Injector Assembly. Refer to UENR4468, Disassembly and Assembly, to remove and install the new DEF Injector Assembly.
2. Update the engine software. Reflash the engine controller (ECM) with the 539-8400 Software Group or latest available on SIS Web.
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%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.