Information injection-pump assembly
ZEXEL
106672-3340
1066723340
HINO
220202850A
220202850a
Rating:
Cross reference number
ZEXEL
106672-3340
1066723340
HINO
220202850A
220202850a
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
134424-0920
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.3
3.2
3.3
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
9.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
130
128
132
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.8+-0.5
Pump speed
r/min
340
340
340
Average injection quantity
mm3/st.
16
13
19
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
----------
K=11
----------
----------
K=11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=8deg+-5deg b=27deg+-5deg
----------
----------
a=8deg+-5deg b=27deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Rack position aa or less, pump speed bb
----------
aa=6.3mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
----------
aa=6.3mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
Information:
COMPLETION DATE
TERMINATION DATE
30Nov2009 31May2010
PROBLEM
Incorrect fuel injectors may be installed on certain AD45B and AD55 Underground Articulated Trucks. The 291-5911 Injector Gp-Fuel listed on SIS Web was the incorrect part number to use for replacement. This only affects machines that may have had an injector or injectors replaced during field service or by the customer. The correct fuel injectors have been installed in the engines from the factory.
AFFECTED PRODUCT
Model Identification Number
AD45B CXM00301-00382, 384-412, 415-420
AD55 ANW00341-00392
DNW00501-00553, 555-574, 576-612
PARTS NEEDED
Qty
Part Number Description
6 2530618 INJECTOR GP-FUEL (IF/AS REQUIRED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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
Remove the engine valve covers and inspect the part number on each fuel injector. Remove any 291-5911 Fuel Injectors from the engine and replace with a 253-0618 Fuel Injector.
For further information on replacing a fuel injector refer to Disassembly and Assembly, RENR8261, "C15 and C18 Engines for Caterpillar Built Machines".
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
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 0.5-hour job
This is a 0.5 hour job to inspect machines for correct injectors. If all six injectors require replacement allow an additional 3.0 hours to replace and to check/adjust valve clearances and injector heights. Individual injectors are to be claimed at an additional 0.3 hours per injector plus 1.0 to check/adjust valve clearances and injector heights
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.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FUEL INJECTORS ON CERTAIN AD45B AND AD55 UNDERGROUND ARTICULATED TRUCKS EQUIPPED WITH A C18 ENGINE
MODELS INVOLVED - AD45B AND AD55 UNDERGROUND ARTICULATED TRUCKS
Dear Caterpillar Product Owner:
The fuel injectors need to be inspected and replaced if found to be incorrect on the products listed below. The incorrect fuel injectors can effect engine emissions and also have an effect on engine performance. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 06May2009 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 06May2009 Service Letter