101491-0720 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910720 8970754240

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-0720 1014910720

ISUZU 8970754240 8970754240

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Service parts 101491-0720 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8870

3. GOVERNOR 105931-9580

4. SUPPLY PUMP 105210-5140

5. AUTOM. ADVANCE MECHANIS 105622-1630

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4683

11. Nozzle and Holder 8-97119-858-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0610

15. NOZZLE SET

Include in #1:

101491-0720 as INJECTION-PUMP ASSEMBLY

Include in #2:

104761-4171 as _

Cross reference number

ZEXEL 101491-0720 1014910720

ISUZU 8970754240 8970754240

Zexel num

Bosch num

Firm num

Name

101491-0720
101491-0721

8970754240 ISUZU

INJECTION-PUMP ASSEMBLY
4BE1 * K

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 10.3

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 45.9 44.3 47.5

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 9.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 12.5 11.2 13.8

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(10.3)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 45.9 44.9 46.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 55.7 51.7 59.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78.5 62.5 94.5

Fixing the lever *

Timer adjustment

Pump speed r/min (1375)

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min (1750)

Advance angle deg. 5 4.5 5.5

Remarks
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.
----------
T1=G35
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=5.5deg+-5deg b=34.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=45deg+-5deg b=29deg+-5deg

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=17deg
----------
a=(90deg)

Information:

Caterpillar: Confidential Yellow
PSP FOR REPLACING UNIT INJECTOR RETURN SPRINGS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785, 789 TRUCKS; 3508, 3512, 351 6 ENGINES - PS4591 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, MARINE TEPS
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.
May 30, 1991 U-110 A-78 AU-66 E-69 O-82 TM-9 PRODUCT SUPPORT PROGRAM FOR REPLACING UNIT INJECTOR RETURN SPRINGS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785, AND 789 TRUCKS; AND 3508, 3512, AND 3516 ENGINES. 1290 PS4591 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 "PS4591" as Part Number, "7755" as Group Number, and "96" as Description Code. Although this Program is to be administered as described above on the Affected Product, parts stock should be reworked as soon as possible. Termination Date
May 31, 1992
Problem
The return springs for Type 2 unit injectors on certain D11N Tractors; 776B Tractors; 777B, 785, and 789 Trucks; and 3508, 3512, and 3516 Engines may fail in some applications. Type 2 injectors are described on