Information injection-pump assembly
ZEXEL
106671-6282
1066716282
ISUZU
1156032163
1156032163
Rating:
Cross reference number
ZEXEL
106671-6282
1066716282
ISUZU
1156032163
1156032163
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-8620
Overflow valve opening pressure
kPa
206
172
240
Overflow valve opening pressure
kgf/cm2
2.1
1.75
2.45
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.5
4.47
4.53
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
149
147
151
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
6.4+-0.5
Pump speed
r/min
290
290
290
Average injection quantity
mm3/st.
10
6.8
13.2
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
149
147
151
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.65
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
161
155
167
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_05
Adjusting point
E
Rack position
R1+0.2
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
149
143
155
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R2-1.75
Boost pressure
kPa
4
4
6.7
Boost pressure
mmHg
30
30
50
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2[R1-0.
45]
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
875
Advance angle
deg.
1.5
1
2
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)Boost compensator stroke: BCL
----------
T1=AE45 BCL=1.75+-0.1mm
----------
----------
T1=AE45 BCL=1.75+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=27deg+-5deg b=32.5deg+-3deg
----------
aa=35mm
----------
a=27deg+-5deg b=32.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=22deg+-5deg b=41deg+-5deg
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=22deg+-5deg b=41deg+-5deg
0000001501 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Lever
1. Aneroid compensator unit adjustment
(1)Screw in (A) to obtain L1.
(2)Select C so that dimension L2 can be obtained.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Set to full boost.
(3)Screw in the aneroid compensator body to obtain the performance shown in the graph above.
(4)As there is hysterisis, measure when the absolute pressure drops.
(5)Hysterisis must not exceed rack position = h1.
----------
N1=800r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3[R1+0.2]mm Rb=(R3-0.4)mm Rc=R3-0.75mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=79.4+-2.7kPa(596+-20mmHg) P3=70.1+-0.7kPa(526+-5mmHg) Q1=(149)+-3cm3/1000st Q2=(138.5)cm3/1000st Q3=(129)+-3cm3/1000st
----------
N1=800r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3[R1+0.2]mm Rb=(R3-0.4)mm Rc=R3-0.75mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=79.4+-2.7kPa(596+-20mmHg) P3=70.1+-0.7kPa(526+-5mmHg) Q1=(149)+-3cm3/1000st Q2=(138.5)cm3/1000st Q3=(129)+-3cm3/1000st
0000001601 TAMPER PROOF
(A): Rotation tamper proof
(B): Full-speed setting
1. Back off the full-speed set bolt.
2. Confirm that the tamper setting position is N1, R1, Q1.
3. At that time, record the angle of the speed lever.
4. After confirming the above setting, set full speed.
----------
N1=1440r/min R1=(7.1)mm Q1=-
----------
----------
N1=1440r/min R1=(7.1)mm Q1=-
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(50deg)
----------
aa=10deg
----------
a=(50deg)
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