Information injection-pump assembly
ZEXEL
101603-0520
1016030520
ISUZU
1156017850
1156017850
Rating:
Cross reference number
ZEXEL
101603-0520
1016030520
ISUZU
1156017850
1156017850
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.7
3.65
3.75
Beginning of injection position
Governor side NO.1
Governor 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
12.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
92.8
91.2
94.4
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
H
Rack position
9.5+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
11.7
9.7
13.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
92.8
91.8
93.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
83.2
80
86.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
R2(13.8)
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
103
103
113
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=B01
----------
----------
T1=B01
----------
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 N2=800r/min C2=(6.4deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=6.4+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C2=(6.4deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=6.4+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18deg+-5deg b=33deg+-3deg
----------
----------
a=18deg+-5deg b=33deg+-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(12.4)mm VR=2+-0.01V
----------
----------
N=- R=R1(12.4)mm VR=2+-0.01V
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
20Oct2015
U-557
A-401
D-483
O-483
TM-15
TA-4
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 20R-0476 INJECTOR ASSEMBLIES FROM DEALER PARTS STOCK
7750 PI70592
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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
31Jan2016
PROBLEM
All 20R-0476 Injector Assemblies in dealer parts stock need to be inspected for the date code. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock. These injector as may have a nozzle assembly marked 2645K015 which is not correct. (Image1 = Incorrect) The correct nozzle assembly should be marked 2645K016. (Image2 = Correct) These two nozzles are not interchangeable.
ACTION REQUIRED
Inspect the date code on all 20R-0476 Injector Assemblies in dealer parts stock. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.