Information injection-pump assembly
ZEXEL
101602-8350
1016028350
ISUZU
1156031970
1156031970
Rating:
Cross reference number
ZEXEL
101602-8350
1016028350
ISUZU
1156031970
1156031970
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
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
9
Pump speed
r/min
725
725
725
Average injection quantity
mm3/st.
71
69.5
72.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.9+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
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.
90
85
95
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
----------
K=11
----------
----------
K=11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Set the pump speed at aa
(3)Set speed at bb (setting at delivery).
----------
aa=750r/min bb=900r/min
----------
a=2deg+-5deg b=15deg+-5deg c=6deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=2deg+-5deg b=15deg+-5deg c=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
----------
----------
a=66.5deg+-5deg b=53deg+-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=14deg
----------
a=(90deg)
----------
aa=14deg
----------
a=(90deg)
Information:
December 9, 2005
U-389
A-289
D-306
O-325
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN FUEL INJECTORS FROM DEALERS PARTS STOCK
7750 PI70111
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2006PROBLEM
A machining error can cause the valve body tocrack through the high-pressure line. This crack can result in fuel inthe engine oil.ACTION REQUIRED
All 10R-0957 unit injectors within serial numberrange 848368-850132 should be removed from parts stock. All 10R-0960, 10R-0961,and 10R-0963 within serial number range 188029-188914 should be removedfrom parts stock.SERVICE CLAIM ALLOWANCES
Submit one claim for all 10R0957, 10R0960, 10R0961,and 10R0963 Injectors removed from parts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70111.***** U.S. and Canadian Dealers *****Return all 10R0957, 10R0960, 10R0961, and 10R0963Injectors that are removed from parts stock and a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery PI70111
Service Claims Room
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
U-389
A-289
D-306
O-325
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN FUEL INJECTORS FROM DEALERS PARTS STOCK
7750 PI70111
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2006PROBLEM
A machining error can cause the valve body tocrack through the high-pressure line. This crack can result in fuel inthe engine oil.ACTION REQUIRED
All 10R-0957 unit injectors within serial numberrange 848368-850132 should be removed from parts stock. All 10R-0960, 10R-0961,and 10R-0963 within serial number range 188029-188914 should be removedfrom parts stock.SERVICE CLAIM ALLOWANCES
Submit one claim for all 10R0957, 10R0960, 10R0961,and 10R0963 Injectors removed from parts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70111.***** U.S. and Canadian Dealers *****Return all 10R0957, 10R0960, 10R0961, and 10R0963Injectors that are removed from parts stock and a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery PI70111
Service Claims Room
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.