Information injection-pump assembly
ZEXEL
101603-0290
1016030290
ISUZU
1156017761
1156017761
Rating:
Cross reference number
ZEXEL
101603-0290
1016030290
ISUZU
1156017761
1156017761
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
-
Rack position
13.8
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
89.9
88.3
91.5
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
-
Rack position
9.7+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
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
A
Rack position
R1(13.8)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
89.9
88.9
90.9
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.45
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
89.2
86
92.4
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.1
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
83.8
80.6
87
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_06
Adjusting point
D
Rack position
12.6
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54.5
52.9
56.1
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
15+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
92
92
100
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
12.6
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
13.1
Boost pressure
kPa
4.7
4.7
7.4
Boost pressure
mmHg
35
35
55
Boost compensator adjustment_03
Pump speed
r/min
550
550
550
Rack position
R1-0.1
Remarks
Measure actual boost pressure.
Measure actual boost pressure.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B04 BCL=(1.1)+-0.1mm
----------
----------
T1=B04 BCL=(1.1)+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4)deg t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4)deg t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg
----------
aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
(g) rack limit
(h) Standard point
(i) pump end face
(j) Apply red paint.
Rack sensor adjustment (154610-0420)
1. Rack limit adjustment
(1)Fix the rack at the rack limit position Rl.
(2)Attach shim (D) [shim thickness standard (17.5 - R1] to rod (C) and tighten nut (E).
(3)Measure the distance X between the end face of the pump and the nut (E), and select a shim (D) so that X = 33-0.2mm.
(4)Release the rack, mount the joint (B) and fix.
(5)At this time, confirm that the shim (D) does not interfere with the joint (B).
2. Rack limit adjustment (amp-equipped type)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at No r/min.
(3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join.
----------
N=- R=R1(13.8)mm VR=2+-0.01V
----------
----------
N=- R=R1(13.8)mm VR=2+-0.01V
----------
Timing setting
(1)Pump vertical direction
(2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Problem
The fuel injection nozzles used in certain D3C, D4C, D4H, D5C, and D5C LGP Tractors; D4H Track Skidders; 931C, 935C, 943, And 953 Loaders; 916 and 926E Loaders; and IT18B and IT28B Tool Carriers may not have had the orifices machined at the correct spray angle. The fuel nozzles in question are 4W7015 Nozzles with a date code of D91, E91, or F91.
Affected Product
Model & Identification Number
D3C (5CJ552-751; 4HJ443-573; 8DG67-105; 7JG76-90; 5ZG48-51)
D4C (7KG469-597; 9BG197-303)
D4H (2AC4156-5522; 3AC4196-4217; 8PB4997-5566; 9DB4798-5058)
D5C (6PJ183-339)
D5C LGP (3MK189-223)
D4H TSK (8ZF53-56)
931C (9AG36-39; 2AK62-66; 6AJ87-101)
935C (5DJ108-151)
943 (19Z1901-1904)
953 (20Z4305-4355; 44Z758-763)
IT18B (2NJ344-390)
IT28B (1JK457-548; 1HF2397-2420)
916 (5KC1832-1924)
926E (4NB3675-3703; 8NB2464-2625)
Parts Needed
1 - 7C7955 Gasket1 - 4W7015 Nozzle AssemblyUse as required (1 to 4 Nozzles May Be Needed)
Action Required
Parts Stock
Remove all 4W7015 Nozzles, that have a date code of D91, E91, or F91, from parts stock.
Affected Product
If excessive quantities of black smoke are noticeable when operating at high idle or under full load conditions, remove and inspect all four of the nozzles. Replace any 4W7015 Nozzle that has a date code of D91, E91, or F91. One or more of the four nozzles may have these date codes.
Service Claim Allowances
Parts Stock
Submit one claim for all 4W7015 Nozzles removed from parts stock.
Affected Product
This is a 3-hour job.
Parts Disposition
U.S. And Canadian Dealers
Return all 4W7015 Nozzles and a copy of the claim to:
Caterpillar Inc.
Attn: Supplier Recovery Supervisor
Warehouse #4 Docks 7 thru 10
8201 N. University
Peoria, IL 61615
CofA
Return all 4W7015 Nozzles and a copy of the claim to:
Caterpillar of Australia
Warranty Claims Area
1 Sharps Rd.
Tullamarine Vic 3043
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
The fuel injection nozzles used in certain D3C, D4C, D4H, D5C, and D5C LGP Tractors; D4H Track Skidders; 931C, 935C, 943, And 953 Loaders; 916 and 926E Loaders; and IT18B and IT28B Tool Carriers may not have had the orifices machined at the correct spray angle. The fuel nozzles in question are 4W7015 Nozzles with a date code of D91, E91, or F91.
Affected Product
Model & Identification Number
D3C (5CJ552-751; 4HJ443-573; 8DG67-105; 7JG76-90; 5ZG48-51)
D4C (7KG469-597; 9BG197-303)
D4H (2AC4156-5522; 3AC4196-4217; 8PB4997-5566; 9DB4798-5058)
D5C (6PJ183-339)
D5C LGP (3MK189-223)
D4H TSK (8ZF53-56)
931C (9AG36-39; 2AK62-66; 6AJ87-101)
935C (5DJ108-151)
943 (19Z1901-1904)
953 (20Z4305-4355; 44Z758-763)
IT18B (2NJ344-390)
IT28B (1JK457-548; 1HF2397-2420)
916 (5KC1832-1924)
926E (4NB3675-3703; 8NB2464-2625)
Parts Needed
1 - 7C7955 Gasket1 - 4W7015 Nozzle AssemblyUse as required (1 to 4 Nozzles May Be Needed)
Action Required
Parts Stock
Remove all 4W7015 Nozzles, that have a date code of D91, E91, or F91, from parts stock.
Affected Product
If excessive quantities of black smoke are noticeable when operating at high idle or under full load conditions, remove and inspect all four of the nozzles. Replace any 4W7015 Nozzle that has a date code of D91, E91, or F91. One or more of the four nozzles may have these date codes.
Service Claim Allowances
Parts Stock
Submit one claim for all 4W7015 Nozzles removed from parts stock.
Affected Product
This is a 3-hour job.
Parts Disposition
U.S. And Canadian Dealers
Return all 4W7015 Nozzles and a copy of the claim to:
Caterpillar Inc.
Attn: Supplier Recovery Supervisor
Warehouse #4 Docks 7 thru 10
8201 N. University
Peoria, IL 61615
CofA
Return all 4W7015 Nozzles and a copy of the claim to:
Caterpillar of Australia
Warranty Claims Area
1 Sharps Rd.
Tullamarine Vic 3043
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.