Information injection-pump assembly
ZEXEL
101603-4582
1016034582
ISUZU
1156022502
1156022502
Rating:
Cross reference number
ZEXEL
101603-4582
1016034582
ISUZU
1156022502
1156022502
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
11.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
74.8
73.2
76.4
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
275
275
275
Average injection quantity
mm3/st.
8
6.7
9.3
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(11.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
74.8
73.8
75.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.35
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
87.3
83.3
91.3
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
93
93
101
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1275--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1225
Advance angle
deg.
0.5
Load
3/4
Timer adjustment_03
Pump speed
r/min
1275
Advance angle
deg.
0.5
Load
4/4
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Torque control stroke: L1
(3)RACK LIMIT
----------
T1=D07 L1=(1.5)mm
----------
----------
T1=D07 L1=(1.5)mm
----------
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=42deg+-5deg b=(38deg)+-3deg
----------
aa=35mm
----------
a=42deg+-5deg b=(38deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 VARIABLE TORQUE CONTROL
N:Pump speed (r/min)
R:Rack position (mm)
Adjusting shim A
Guide screw B
(c) Nut
(d) Nut
(e) nut
Torque control spring adjustment method for model responding to speed droop
[Advice]
Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment.
(1)Temporary idle lever position setting
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
(2)Idling spring adjustment
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
(3)Governor spring setting adjustment
1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor.
2. Set the control lever where it contacts the idle stopper bolt.
3. Increase the speed to Nh2+100 r/min or more.
4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily.
5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E).
6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily.
[Advice]
When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min.
Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change.
(4)Full load position setting
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
(5)Torque control spring adjustment
1. Set the control lever so that it contacts the full speed stopper bolt.
2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily.
3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily.
4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf.
5. Set the speed at Nf-50 r/min.
6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A).
7. After completing shim adjustment, repeat the above adjustment using the two nuts.
8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D).
9. In this condition, increase the speed and confirm that R = 0 can be obtained.
(6)Full speed lever position setting
1. Set the control lever so that it contacts the full speed stopper bolt.
2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily
3. Increase the speed and confirm that the specified rack position Ru can be obtained.
4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix.
5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.'
6. Confirm that the control lever operating angle is within the specifications.
(7)Rack limit adjustment
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
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----------
----------
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Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(60deg)
----------
aa=12deg
----------
a=(60deg)
Information:
03May2017
U-247
A-163
D-194
O-200
TM-3
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING CERTAIN REMAN FUEL INJECTORS IN DEALER PARTS STOCK
7750 PI70664
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
31Aug2017
PROBLEM
Certain Reman fuel injectors were labeled with the same "2755" trim code from January 9, 2017 through April 18, 2017. The injector serial numbers of suspect injectors are 1825569 through 1880788. The trim code may or may not be correct. Image 1 shows a suspect trim code.
Parts from part distribution centers have been inspected and the boxes have been marked with a large green dot to indicate the injector has been inspected, marked correctly, or the trim code is correct. Refer to Image 2.
ACTION REQUIRED
Inspect the following Reman injectors in dealer parts stock:
20R0848
20R0849
20R0850
20R0863
20R0864
20R1264
20R1265
20R1266
20R1268
20R1269
20R1270
20R1271
20R1272
20R1273
20R1274
20R1275
20R1276
20R1277
20R1278
20R1279
20R1280
20R1281
20R1282
20R1283
20R2296
20R3247
20R3477
20R3479
20R3480
20R3483
Inspect the date code on the box.
If the date code on the box is not January 9, 2017 through April 18, 2017, then mark the box as inspected per this program and place the part back in dealer parts stock.
If the date code on the box is January 9, 2017 through April 18, 2017, then inspect the injector trim code.
If the trim code is not "2755", then mark the box as inspected per this program and place the part back in dealer parts stock.
If the trim code is "2755", then inspect the injector serial number using the following inspection and rework the procedure:
Use the following web address and download the spreadsheet file:
https://cat.box.com/s/4fwh9nz0lwguh8vomifxj2rapqjc27e9
Use the downloaded file. Type in the injector serial number to check the trim code. The spreadsheet will return whether the trim code is OK to use, or rework and mark the injector with the correct trim code.
Note: Some injector serial numbers will show "2755" as the correct trim code.
If the trim code is correct (acceptable trim code), record the injector serial number, then mark the box as inspected per this program and place the part back in dealer parts stock.
If the trim code is not correct (rework), the injector must be relabeled. Use an engraving tool to cross out the original trim code and write the correct trim code as shown in Image 3. Record the injector serial number and the updated/corrected trim code, then mark the box as reworked per this program and place the part back in dealer parts stock.
Image1
Image2
Image3
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts inspected and reworked from dealer parts stock.