101491-0762 ZEXEL 9 400 610 528 BOSCH INJECTION-PUMP ASSEMBLY 9400610528 1014910762 8970798962

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 528 9400610528

ZEXEL 101491-0762 1014910762

ISUZU 8970798962 8970798962

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Buy INJECTION-PUMP ASSEMBLY 101491-0762 zexel genuine, new aftermarket engine parts with delivery

Service parts 101491-0762 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8870

3. GOVERNOR 105931-8672

4. SUPPLY PUMP 105210-6140

5. AUTOM. ADVANCE MECHANIS 105622-1631

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:

101491-0762 as INJECTION-PUMP ASSEMBLY

101605-3000 as _

Cross reference number

BOSCH 9 400 610 528 9400610528

ZEXEL 101491-0762 1014910762

ISUZU 8970798962 8970798962

Zexel num

Bosch num

Firm num

Name

101491-0762

9 400 610 528

8970798962 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 10.4

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 52 50.4 53.6

Max. variation between cylinders % 0 -4 4

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(10.4)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 52 51 53

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. 64.5 61.3 67.7

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 1425--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1375

Advance angle deg. 0.5

Timer adjustment_03

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:

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
March 31, 1997Problem
Improvements have been made to the remanufactured unit injectors that are used in various 3114 and 3116 Engines. All of the former 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors need to be removed from Parts Stock.
Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors from Parts Stock.
When ordering parts, refer to the attached chart until the information is available in a permanent publication.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors removed from Parts Stock.
TEPS Dealers should refer to their warranty bullitin for proper claiming and disposition.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors 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".
Attach.(1-UNIT INJECTOR CHART)3114 & 3116 Unit Injector Chart