104741-6720 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047416720 8970189430

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-6720 1047416720

ISUZU 8970189430 8970189430

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Cross reference number

ZEXEL 104741-6720 1047416720

ISUZU 8970189430 8970189430

Zexel num

Bosch num

Firm num

Name

104741-6720
104741-6723

8970189430 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1-TC *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

(Solenoid timer adjustment condition) OFF

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 750 750 750

Boost pressure kPa 42.7 41.4 44

Boost pressure mmHg 320 310 330

Average injection quantity mm3/st. 50.5 50 51

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1100 1100 1100

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 67.7 67.2 68.2

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.1 38.1 38.1

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 600 600 600

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Average injection quantity mm3/st. 38.6 38.6 38.6

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 42.7 41.4 44

Boost pressure mmHg 320 310 330

Average injection quantity mm3/st. 50.5 49.5 51.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1100 1100 1100

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 67.7 66.7 68.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1100 1100 1100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 53.1 53.1 53.1

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1900 1900 1900

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 71.2 71.2 71.2

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 23.4 20.4 26.4

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2400 2400 2400

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 12

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 23.4 20.4 26.4

Difference in delivery mm3/st. 7

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5.6 3.6 7.6

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5.6 3.6 7.6

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 85 80 90

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 85 80 90

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Overflow quantity with S/T ON cm3/min 560 430 690

Overflow quantity with S/T OFF cm3/min 640 510 770

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure with S/T OFF kPa 490 470 510

Pressure with S/T OFF kgf/cm2 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure with S/T OFF kPa 412 373 451

Pressure with S/T OFF kgf/cm2 4.2 3.8 4.6

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure with S/T OFF kPa 490 461 519

Pressure with S/T OFF kgf/cm2 5 4.7 5.3

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure with S/T OFF kPa 559 520 598

Pressure with S/T OFF kgf/cm2 5.7 5.3 6.1

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 1900 1900 1900

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure with S/T OFF kPa 618 579 657

Pressure with S/T OFF kgf/cm2 6.3 5.9 6.7

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke with S/T OFF mm 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 425 425 425

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke with S/T ON mm 1.2

Oil temperature degC 48 46 50

_03

Pump speed r/min 750 750 750

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke with S/T ON mm 1 1

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke with S/T OFF mm 1.3 0.9 1.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke with S/T OFF mm 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

_06

Pump speed r/min 1900 1900 1900

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke with S/T OFF mm 7.4 7.1 7.8

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 1 0.9 1.1

BCS stroke mm 2.7 2.5 2.9

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 24 20 28

Control lever angle beta deg. 48 43 53

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjust the potentiometer so that the output voltage is V1 at the idle lever position (applied voltage Vi).
----------
V1=1.3+-0.03V Vi=10V
----------

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain S1. 2. Apply negative pressure P1 to the actuator and confirm the full stroke. (A) Control lever (Idling position)
----------
S1=1+1mm P1=-53.3kPa(-400mmHg)
----------
S1=1+1mm

0000002001 A/T PLATE ADJUSTMENT

A/T plate adjustment Adjust the A/T plate (A) so that (A)(C) - (A)(B) = L3 when the control lever is moved from the idle position (B) to the full speed position (C), then fix. (B) Idle position (C) Full
----------
L3=32.9+-1mm
----------
L1=36mm L2=174mm

0000002101 STARTING I/Q ADJUSTMENT

Starting injection quantity adjustment Adjust adjusting bolt (A) so that the start injection quantity is within the specifications and fix using nut (B). (Torque T) Make bolt protrusion L.
----------
L=3~6mm T=3.4~4.9N-m(0.35~0.5kgf-m)
----------
L=3~6mm T=3.4~4.9N-m(0.35~0.5kgf-m)

Information:

Caterpillar: Confidential Yellow
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PS0456 - US, CANADA, CACO, LTD COFA - REVISED 10/90
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.
(Revised October 1990) U-130 A-88 AU-86.1 1100, 1290 PS0456 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0456" as Part Number, "7755" as Group Number, and "96" as Description Code. If this Program is administered on E200B or EL200B Excavators, it is recommended that the June 22, 1990 Service Letter - PS4442 be done at the same time. This Revised Service Letter replaces the June 25, 1990 Service Letter. Changes have been made to add Affected Product. Termination Date
June 30, 1991
Problem
The fuel injector sleeves in the cylinder head of certain IT14B Integrated Toolcarriers; E110B, E120B, E200B, EL200B, 213B, 214B, 224B, E240B, and EL240B Excavators; 446 Backhoe Loaders; CB-434, CP-563, and CS-563 Compactors; AP-1050 Asphalt Pavers; and 3114 and 3116 Industrial and Generator Set Engines are subject to pitting and erosion due to fuel cavitation between the injector and the sleeve. The sleeves may pit or crack through, allowing fuel to contaminate the coolant. Coolant contaminated with fuel may also damage the radiator and coolant hoses.
Affected Product
Model Identification Number IT14B 3NJ1-42 E110B 8MF1-151 E120B 6JF1-212 E200B* 6KF1-439 6KG1-249 EL200B* 7DF1-986 213B 1EJ1-233, 236-245, 247, 248 214B