Information injection-pump assembly
ZEXEL
104304-4180
1043044180
ISUZU
8941447720
8941447720
Rating:
Cross reference number
ZEXEL
104304-4180
1043044180
ISUZU
8941447720
8941447720
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
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
1-3-4-2
Pre-stroke
mm
2.1
2.05
2.15
Rack position
Point B R=B
Point B R=B
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
8.2
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
29
28.5
29.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.2
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
27.2
25.2
29.2
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.1+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-14
14
Fixing the lever
*
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_04
Adjusting point
E
Rack position
-
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
28.5
27.5
29.5
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque control stroke: L1
(2)Set the idle spring.
(3)Main spring setting
(4)Rack difference between N = N1 and N = N2
(5)Rack difference between N = N3 and N = N4
----------
L1=1.2mm N1=1300r/min N2=1000r/min N3=1300r/min N4=700r/min
----------
----------
L1=1.2mm N1=1300r/min N2=1000r/min N3=1300r/min N4=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=8deg+-3deg b=30deg+-6deg
----------
----------
a=8deg+-3deg b=30deg+-6deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (same as key groove position)
(3)B.T.D.C.: aa
(4)-
----------
aa=17deg
----------
a=(50deg)
----------
aa=17deg
----------
a=(50deg)
Information:
PARTS NEEDED
Qty
Part Number Description
80 6V5839 WASHER-HARD
80 8T2223 BOLT-SOCKET HD
20 20R5566 INJECTOR GP-F -G
1 SOFTWARE See Note in Action Required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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
****Parts Stock ****
Rework the following engines in dealer parts stock and/or dealer exchange inventory:
797F LAA/HAA
For engine arrangements 2621300, 2822060, 2863503, 3981020, 330-0200, 2863503, 3601647, 3659323, 3659326, 3659327, 3659328, 3659329, 4170588, 188764, 4213013, 4213014, 4233501, 4233502, 20R1363, 20R1494, 20R1495, 20R1496, 20R4668
Service Replacement C175-20 Engines with a LLM, A4K, ZK3, H4N.
Disassemble and replace the former 3315895 or 10R8998 Fuel Injector with the the 20R5566 Fuel Injector in reconditioned or reman engines or the new 4439454 Fuel Injector in new engines in dealer exchange inventory.
Refer to KENR6052-11 R&I Electronic Unit Injector
New engine software is required to support the new fuel injector. Engines must be equipped with the new engine software listed in M0067056.
****Affected Product****
Replace the existing 331-5895 Fuel Injectors or the 10R8998 Fuel Injectors with the new 20R-5566 Fuel Injectors. Refer to the service manual as necessary.
Refer to KENR6052-11 R&I Electronic Unit Injector
Engines must be equipped with the new engine software listed in M0067056.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for each engine reworked in dealer parts stock. For Reman engine refer to the Parts Needed. For new engines 80 - 6V5839 Washers, 80 - 8T2223 Bolts, 20 - 4439454 Injectors and latest software plus 7 hours of labor will be allowed for each engine that is reworked in dealer parts stock inventory.
Include engine serial number in additional comments field of the claim.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 14.0-hour job
When applicable reasonable travel time and mileage will be allowed.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.