Information injection-pump assembly
ZEXEL
101696-9470
1016969470
NISSAN-DIESEL
16713Z6514
16713z6514
Rating:
Cross reference number
ZEXEL
101696-9470
1016969470
NISSAN-DIESEL
16713Z6514
16713z6514
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
Overflow valve
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
3.9
3.85
3.95
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
13
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
98.5
96.5
100.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
6.2
9.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
98.5
97.5
99.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.05
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
103
99.8
106.2
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
4)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
74.5
71.3
77.7
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.1
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
55.5
52.3
58.7
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
90
90
110
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
R2-1.1
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
R2(R1-0.
4)
Boost pressure
kPa
23.3
23.3
23.3
Boost pressure
mmHg
175
175
175
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
0
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
450
Advance angle
deg.
1
0.5
1.5
Timer adjustment_04
Pump speed
r/min
(530)
Advance angle
deg.
0
0
0
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_05
Pump speed
r/min
1120
Advance angle
deg.
0.5
Timer adjustment_06
Pump speed
r/min
1400
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
----------
T1=L10 BCL=1.1+-0.1mm
----------
----------
T1=L10 BCL=1.1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=39mm
----------
a=20deg+-5deg b=39deg+-3deg
----------
aa=39mm
----------
a=20deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)No return spring
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack limit adjustment
(1)Fix the rack at the rack limit position Ra.
(2)Install the shim (D) to the rod (C) and tighten nut (E).
(3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L.
(4)Release the rack fixing and mount the joint (B) and fix.
(5)At this time, confirm that the shim (D) does not interfere with the joint (B).
2. Rack sensor adjustment (-0420)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set the speed to N1 r/min.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.02 V, then tighten the nut (F).
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=700r/min Ra=R1(13)mm
----------
----------
L=33-0.2mm N1=700r/min Ra=R1(13)mm
----------
0000001601 LEVER
(a) Speed lever
(B) Accelerator lever
(C) Accelerator lever stopper bolt
1. Accelerator lever setting method
With the speed lever in the idling position, back off the accelerator lever stopper bolt L1 from where it contacts point a. (Back off 1+0.5 turns and set.)
----------
L1=1+0.5mm
----------
----------
L1=1+0.5mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
PROBLEM
The diesel oxidation catalysts needs to be reworked or replaced on certain 3512E Petroleum Engines. The existing diesel oxidation catalysts can crack on the top panel and cause an exhaust leak.
AFFECTED PRODUCT
Model Identification Number
3512E NG400100-00127
NG500100-00130
PARTS NEEDED
Qty
Part Number Description
2 3031968 GASKET
4 3460335 CLAMP-BAND
4 5365400 PLATE (Before Failure-See Action Required)
2 5492046 MODULE AR-EXH (After Failure-See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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
There is currently a limited supply of parts available for this program. The 549-2046 Part Name is frozen and allocation will be manually prioritized until sufficient quantities are available. Please work with your Customer Service Representative for parts availability.
Refer to the Safety Section in the Operation and Maintenance Manual prior to conducting any service work.
Inspect the existing diesel oxidation catalysts for cracks.
If no cracks are present, refer to Special Instruction, M0116373 for welding rails onto the top of the diesel oxidation catalysts.
If cracks are present, the diesel oxidation catalysts will need to be replaced.
OWNER NOTIFICATION
Owners in the following countries will receive the attached Owner Notification:
US
Canada
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 6.0-hour job
6.0 hours for after failure for replacing DOC's.
10.0 Hours for before failure for R&I of DOC's and welding.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
EXAMPLE COPY OF OWNER NOTIFICATION
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING OR REPLACING THE DIESEL OXIDATION CATALYSTS
MODELS INVOLVED - CERTAIN 3512E PETROLEUM ENGINES
Dear Cat Product Owner:
The Diesel Oxidation Catalysts need to be reworked or replaced on the products listed below. The existing Diesel Oxidation Catalysts can crack on the top panel and cause an exhaust leak. You will not be charged for the service performed.
Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 12Mar2020 when scheduling this service.
We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 12Mar2020 Service Letter