Information injection-pump assembly
ZEXEL
106672-9430
1066729430
Rating:
Cross reference number
ZEXEL
106672-9430
1066729430
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 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)
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
3.8
3.75
3.85
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
118.1
116.1
120.1
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
Injection quantity adjustment_02
Adjusting point
C
Rack position
4.2+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
13.3
11.8
14.8
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
9.9
Boost pressure
kPa
21.3
18.6
24
Boost pressure
mmHg
160
140
180
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
10.3
Boost pressure
kPa
40
40
40
Boost pressure
mmHg
300
300
300
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Boost compensator stroke
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=13 N1=900r/min N2=625r/min N3=900r/min N4=400r/min
----------
----------
K=13 N1=900r/min N2=625r/min N3=900r/min N4=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=38deg+-5deg b=29deg+-5deg c=0deg+-3deg
----------
----------
a=38deg+-5deg b=29deg+-5deg c=0deg+-3deg
0000001501 LEVER
(F) P/N: Part number of the shim
L1:Thickness (mm)
1. Adjustment of the control lever
(1)Perform idling with the control lever (A) contacting the pushrod (B). At this time, confirm that the spring (C) is not compressed by control lever (A)'s operating torque.
(2)To set the stop position, compress spring (C) using the control lever (A) and adjust the rack so that it contacts the guide screw (D) at position L2. Then, set and fix using the lock nut (E). Adjust the rack position L2 at this time using the shim (F).
(3)Confirm that the control lever (A) returns to the idling position when pulled in the stop direction and then released.
----------
L2=0.2~2mm
----------
----------
L2=0.2~2mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(150deg)
----------
----------
a=(150deg)
Information:
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
August 31, 1997Problem
0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 need to be removed from Parts Stock.Action Required
Inspect all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 15, 1995 at plant number 068).
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
Where the numbers for the months and years are coded as follows:
January 1997 ... NUDKFebruary 1997... NMDKMarch 1997 ... NEDKApril 1997 ... NRDKTo inspect the injectors, push the rack bar in against the trim adjustment screw (the fuel off position). On the flat "D" section of the rack bar extending out of the injector and beyond the rack teeth, inspect for a shinny grooved machine mark completely across the flat surface and parallel with the rack teeth. This mark is caused by the plunger gear contacting the flat of the rack bar If the mark is present, the injector should be returned to Caterpillar.
Service Claim Allowances
Submit one claim for all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 removed from Parts Stock.
MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".
Termination Date
August 31, 1997Problem
0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 need to be removed from Parts Stock.Action Required
Inspect all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 15, 1995 at plant number 068).
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
Where the numbers for the months and years are coded as follows:
January 1997 ... NUDKFebruary 1997... NMDKMarch 1997 ... NEDKApril 1997 ... NRDKTo inspect the injectors, push the rack bar in against the trim adjustment screw (the fuel off position). On the flat "D" section of the rack bar extending out of the injector and beyond the rack teeth, inspect for a shinny grooved machine mark completely across the flat surface and parallel with the rack teeth. This mark is caused by the plunger gear contacting the flat of the rack bar If the mark is present, the injector should be returned to Caterpillar.
Service Claim Allowances
Submit one claim for all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 removed from Parts Stock.
MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".