Information injection-pump assembly
ZEXEL
101491-0701
1014910701
ISUZU
8970754251
8970754251
Rating:
Service parts 101491-0701 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97021-703-1
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-0701
1014910701
ISUZU
8970754251
8970754251
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
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
1-3-4-2
Pre-stroke
mm
3.85
3.8
3.9
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.4
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
58.8
57.2
60.4
Max. variation between cylinders
%
0
-2.5
2.5
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
325
325
325
Average injection quantity
mm3/st.
13.3
12
14.6
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.4)
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
58.8
57.8
59.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
77.1
73.1
81.1
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
92
92
124
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1530--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1480
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1775
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)At delivery (at R = point A, N = aa)
----------
T1=G20 aa=100r/min
----------
----------
T1=G20 aa=100r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)Set the idle side stopper bolt at speed = aa and rack position = bb (at delivery)
----------
aa=100r/min bb=R1(12.4)mm
----------
a=(8deg) b=(38deg)+-3deg c=4deg+-5deg
----------
aa=100r/min bb=R1(12.4)mm
----------
a=(8deg) b=(38deg)+-3deg c=4deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg
0000001501 I/P WITH LOAD PLUNGER ADJ
Plunger assembly number: PL (stamping: ST)
1. Adjustment procedures
(1)Insert the pre-stroke adjusting shims L1 for each cylinder.
(2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2)
(3)At basic point A, adjust so that the pre-stroke is L2.
(4)Reconfirm the injection quantity.
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.85+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.85+-0.05mm a1=+-14% a2=+-2.5%
----------
0000001601 FICD
1. FICD adjustment
(1)FICD adjustment not necessary.
(2)Set the clearance between the actuator rod and speed lever to approx. L1.
----------
L1=3+1mm
----------
----------
L1=3+1mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(90deg)
----------
aa=15deg
----------
a=(90deg)
Information:
Caterpillar: Confidential Yellow
PSP FOR FUEL INJECTION LINE FAILURES ON 627E, 627E PP AND 637E SCRAPERS - MAILED WORLDWIDE EXCEPT BRAZIL
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.
U-35 A-20 AU-22 E-18 O-21 1252 PS4200 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4200" as Part Number and "7755" as Group Number. Termination Date
February 28, 1989
Problem
The fuel injection lines on 627E, 627E PP and 637E Scrapers may crack as a result of excessive vibration. New fuel injection lines and supporting brackets can be installed.
Affected Product
Model Identification Number 627E 6EBl - 513 627E PP 6GB513 - 177, 579-582, 584, 585, 587, 588, 590-603 637E 1FB1 - 338, 341-348, 350-352 1JB1 - 548, 550, 553, 555, 556, 558-561, 563
Parts Needed
1 - 7C9564 Line As. 1 - 7C9565 Line As. 1 - 7C9566 Line As. 11 - 1W9168 Clamp 8 - 5P4939 Screw As. 11 - lW9169 Clamp 1 - 9Y1586 Bracket As. 1 - 9Y1653 Bracket As. 3 - 9N3388 Screw 1 - 9Y2681 Bar (as needed) The 9Y2681 Bar is only needed if the engine is not equipped with heat shields.
Action Required
Install the new parts as shown in the attached illustration. It is important that the 1W9168 and 1W9169 Clamps be installed at the locations shown in the illustration.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first 0-2500
PSP FOR FUEL INJECTION LINE FAILURES ON 627E, 627E PP AND 637E SCRAPERS - MAILED WORLDWIDE EXCEPT BRAZIL
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.
U-35 A-20 AU-22 E-18 O-21 1252 PS4200 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4200" as Part Number and "7755" as Group Number. Termination Date
February 28, 1989
Problem
The fuel injection lines on 627E, 627E PP and 637E Scrapers may crack as a result of excessive vibration. New fuel injection lines and supporting brackets can be installed.
Affected Product
Model Identification Number 627E 6EBl - 513 627E PP 6GB513 - 177, 579-582, 584, 585, 587, 588, 590-603 637E 1FB1 - 338, 341-348, 350-352 1JB1 - 548, 550, 553, 555, 556, 558-561, 563
Parts Needed
1 - 7C9564 Line As. 1 - 7C9565 Line As. 1 - 7C9566 Line As. 11 - 1W9168 Clamp 8 - 5P4939 Screw As. 11 - lW9169 Clamp 1 - 9Y1586 Bracket As. 1 - 9Y1653 Bracket As. 3 - 9N3388 Screw 1 - 9Y2681 Bar (as needed) The 9Y2681 Bar is only needed if the engine is not equipped with heat shields.
Action Required
Install the new parts as shown in the attached illustration. It is important that the 1W9168 and 1W9169 Clamps be installed at the locations shown in the illustration.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first 0-2500