Information injection-pump assembly
ZEXEL
101671-9690
1016719690
Rating:
Service parts 101671-9690 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-95000
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Include in #1:
101671-9690
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-8441
as _
Cross reference number
ZEXEL
101671-9690
1016719690
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
2.5
2.45
2.55
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
12.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
64.7
63.3
66.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
58.3
55.7
60.9
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.2+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.3
7.1
9.5
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
300
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
600
Advance angle
deg.
1.3
0.8
1.8
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
3.5
3
4
Timer adjustment_04
Pump speed
r/min
1400
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)RACK LIMIT: RAL
----------
DL=7.7-0.2mm RAL=12.7+-0.1mm
----------
----------
DL=7.7-0.2mm RAL=12.7+-0.1mm
----------
0000000901
F:Full load
I:Idle
S:Stop
----------
----------
a=39deg+-3deg b=10.5deg+-3deg c=13deg+-5deg
----------
----------
a=39deg+-3deg b=10.5deg+-3deg c=13deg+-5deg
Information:
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
This Program must be administered either before or after failure.In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44681" as the Part Numberand "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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.
TERMINATION DATE
31Mar2017
PROBLEM
The existing injectors can misfire on certain D7R Track-Type Tractors. If the existing injectors fail it can cause the poppet valve seizure in the injector.
AFFECTED PRODUCT
Model Identification Number
D7R II KNA00214-00217, 219-781
PARTS NEEDED
Qty
Part Number Description
6 20R0055 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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
Replace all six injectors. Reference the Disassembly and Assembly Manual for service instructions.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 6.0-hour job
If necessary, reasonable Travel Time and Mileage is allowed.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.