Information injection-pump assembly
ZEXEL
101492-4030
1014924030
ISUZU
8972306200
8972306200
Rating:
Service parts 101492-4030 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97211-280-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-4030
1014924030
ISUZU
8972306200
8972306200
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
131424-0820
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
2.6
2.55
2.65
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
A
Rack position
8.3
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
56
55
57
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.5+-0.5
Pump speed
r/min
540
540
540
Average injection quantity
mm3/st.
11.5
9.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
105
115
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Set at delivery
----------
K=8
----------
----------
K=8
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=1deg+-5deg b=17deg+-5deg c=35deg+-3deg
----------
----------
a=1deg+-5deg b=17deg+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'W' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(210deg)
----------
aa=12deg
----------
a=(210deg)
Information:
PROBLEM
The existing diesel exhaust fluid manifold can fail on certain 2570D, 2670D, 563D, and 573D Wheel Feller Bunchers, and 525D, 535D, 545D, and 555D Wheel Skidders. If the existing DEF manifold fails it can lead to inducements and eventual engine shutdown.
AFFECTED PRODUCT
Model Identification Number
2570D D2500112-00114
2670D D2600208-00211
525D GKP00477-00524, 527
535D MTP00386-00448, 450-453
545D KGP00254-00284, 287
555D PGY00153-00159
563D D6300115-00146
573D D7300209-00226
PARTS NEEDED
Qty
Part Number Description
1 3915262 GASKET
1 5280527 MANIFOLD GP
1 DCUSOFTWARE DCU SOFTWARE
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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
Update the Engine and DCU software files to the latest available in SIS Web. Replace the existing diesel exhaust fluid manifold with the 528-0527 diesel exhaust fluid manifold. Use a new 391-5262 gasket when installing a new manifold.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
6001-8000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.