101681-9200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016819200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101681-9200 1016819200

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Cross reference number

ZEXEL 101681-9200 1016819200

Zexel num

Bosch num

Firm num

Name

101681-9200

DAEWOO

INJECTION-PUMP ASSEMBLY
6BB1 *

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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 2.2 2.15 2.25

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 10.8

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 52.8 51.3 54.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point D

Rack position 7.6+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Timer adjustment

Pump speed r/min 500+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 2.7 2 3.4

Timer adjustment_04

Pump speed r/min 1400

Advance angle deg. 4.4 3.7 5.1

Timer adjustment_05

Pump speed r/min 1630

Remarks
Measure the actual advance angle.

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 6 6 6

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Torque control stroke (3)RACK CAP: R1
----------
K=8 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=25deg+-5deg

Information:

Introduction
The problem that is identified now has a known permanent solution. Components to perform repairs are limited at this time. Review the solution below for further details. Problem
Caterpillar is aware of recent failures of the 8N-1721 Connecting Rod and the 8N-1984 Connecting Rod on certain diesel and gas applications of 3300 engines. Primary failure mode is a ventilated cylinder block due to the connecting rod crank end failure. All failures have occurred before 500 hours in service. Root cause has been identified and the team is working to resolve the issue. Solution
A "Quality Hold" is active for all new assemblies that utilize the 8N-1984 Connecting Rod and the 8N-1721 Connecting Rod manufactured between 01April 2011 and 31December 2012. The "Quality Hold" is applicable to all Morton service stock also.Cat ® Reman has identified a list of part numbers for Service kits, Piston Packs, and Rod Assembly boxes that may contain defective factory connecting rod assemblies. Dealers are advised not to use any factory new connecting rod assemblies that are found in the kits or assemblies prior to examination. Refer to Table 1.
Table 1
Service kit, Piston Pack, and Rod Assembly Part Numbers That May Contain the Defective New Connecting Rod Assemblies
8N-1721 20R-1439 20R-1474
0R-1696 20R-1428 20R-1660
0R-1697 0R-9206 20R-1442
0R-3043 20R-1462 20R-1482
10R-3637 20R-1455 20R-1483
10R-9259 20R-1477 20R-1451
0R-1694 20R-1472 20R-1450
0R-4284 20R-1448 20R-1445
0R-1695 20R-1446 20R-1443
0R-4635 20R-1468 20R-1426
0R-4488 20R-1466 20R-1423
0R-4506 20R-1441 0R-2078
0R-3044 20R-1437 0R-3258
0R-2080 20R-1435 20R-1665
0R-3259 20R-1434 20R-1663
0R-3612 20R-1429 20R-1675
0R-3610 20R-1424 0R-3661
10R-6152 0R-2557 0R-1692
20R-1673 0R-2079 0R-1693
20R-1664 20R-1341 0R-3660
0R-4949 0R-2555 0R-3662
0R-9205 0R-3613 20R-1127
0R-2556 0R-4956 8N-1984
0R-3706 0R-2554
10R-1851 0R-4948
10R-1636 10R-0889
10R-1840 0R-3611
0R-2077 10R-7253
20R-1454 0R-7444 When an engine failure occurs due to the connecting rod assembly, dealers are asked to contact the Dealer Solution Network (DSN) Tier 2 core engine service engineer at Mossville Engine Center (MEC) to expedite support to the customer.To support field repairs and rebuilds, dealers are advised to inspect the manufacture date on any 3304, G3304, 3306, or G3306 engine with the 8N-1984 Connecting Rod , the 8N-1721 Connecting Rod , the 0R-0914 Connecting Rod , and the 0R-0915 Connecting Rod , used to perform repairs. If the manufacture date is within the suspect date range, do not use the part. Parts stocking service letters will be released soon to address suspect material in dealer inventories. Markings on the Suspect 8N-1984 Connecting Rod and the 8N-1721 Connecting Rod
Illustration 1 g03342875
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