Information injection-pump assembly
ZEXEL
104741-6790
1047416790
ISUZU
8970134690
8970134690
Rating:
Cross reference number
ZEXEL
104741-6790
1047416790
ISUZU
8970134690
8970134690
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105000-2010
Bosch type code
NP-DN12SD12TT
Nozzle holder
105780-2080
Opening pressure
MPa
14.7
14.7
15.19
Opening pressure
kgf/cm2
150
150
155
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840
Inside diameter - outside diameter - length (mm) mm 2-6-840
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
Right R
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
42
41.5
42.5
Difference in delivery
mm3/st.
3.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2100
2100
2100
Average injection quantity
mm3/st.
10.7
7.2
14.2
Injection timing adjustment_03
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
47.8
44.3
51.3
Injection timing adjustment_04
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
44.2
41.2
47.2
Injection timing adjustment_05
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
42
41
43
Injection timing adjustment_06
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
34.6
31.1
38.1
Injection timing adjustment_07
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
38.5
34
43
Injection quantity adjustment
Pump speed
r/min
2100
2100
2100
Average injection quantity
mm3/st.
10.7
7.7
13.7
Difference in delivery
mm3/st.
4
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
5
Governor adjustment
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
5.5
3.5
7.5
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
3
Governor adjustment_03
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
5.5
3.5
7.5
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
20
100
Basic
*
Speed control lever angle
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1600
1600
1600
Overflow quantity with S/T ON
cm3/min
489
360
618
Overflow quantity with S/T OFF
cm3/min
579
450
708
Stop lever angle
Pump speed
r/min
1600
1600
1600
Pressure
kPa
460.5
431
490
Pressure
kgf/cm2
4.7
4.4
5
Basic
*
Stop lever angle_02
Pump speed
r/min
1600
1600
1600
Pressure with S/T OFF
kPa
460.5
431
490
Pressure with S/T OFF
kgf/cm2
4.7
4.4
5
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure with S/T OFF
kPa
539.5
500
579
Pressure with S/T OFF
kgf/cm2
5.5
5.1
5.9
0000001101
Pump speed
r/min
1600
1600
1600
Timer stroke
mm
2.2
2
2.4
Basic
*
_02
Pump speed
r/min
900
900
900
Timer stroke with S/T ON
mm
0.5
0.5
_03
Pump speed
r/min
1500
1500
1500
Timer stroke with S/T OFF
mm
0.5
_04
Pump speed
r/min
1600
1600
1600
Timer stroke with S/T OFF
mm
2.2
1.9
2.5
_05
Pump speed
r/min
1700
1700
1700
Timer stroke with S/T OFF
mm
5.1
4.1
6.1
_06
Pump speed
r/min
1800
1800
1800
Timer stroke with S/T OFF
mm
7
6.6
7.4
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
Timing setting
K dimension
mm
2.8
2.7
2.9
KF dimension
mm
5
4.9
5.1
MS dimension
mm
1
0.9
1.1
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
18
14
22
Control lever angle beta
deg.
31
26
36
Test data Ex:
0000001801 V-FICD ADJUSTMENT
Adjustment of the V-FICD
1. Adjust to obtain S.
2. Set at L when negative pressure P1 is applied to the actuator.
To adjust the stroke adjust the actuator's stroke adjusting screw (C).
(A) Control lever
(B) Lock nut (Tightening torque T)
(C) Stroke adjusting screw
----------
S=1+1mm L=1.6+-0.2mm P1=-46.7kPa(-350mmHg) T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
S=1+1mm L=1.6+-0.2mm T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
S=1+1mm L=1.6+-0.2mm P1=-46.7kPa(-350mmHg) T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
S=1+1mm L=1.6+-0.2mm T=1.2~1.5N-m(0.12~0.15kgf-m)
0000001901 A/T PLATE ADJUSTMENT
A/T plate adjustment
Rotate the control lever from the idle position (B) to the full-speed position (C).
Adjust the A/T plate (A) so that (A) (C) - (A) (B) = L1, and fix.
When fixing, fix the A/T plate within the range L3 from the center of the control lever's wire hole (hole L2).
(B) Idle position
(C) Full position
----------
L1=32.9+-1mm L2=Dia.8.5mm L3=Dia.9.2mm
----------
L3=Dia.9.2mm L4=169.8mm L5=12.4mm a=18+-4deg
----------
L1=32.9+-1mm L2=Dia.8.5mm L3=Dia.9.2mm
----------
L3=Dia.9.2mm L4=169.8mm L5=12.4mm a=18+-4deg
0000002001 POTENTIOMETER ADJUSTMENT
Adjust the potentiometer so that the output voltage is V1 at the idle lever position (applied voltage Vi).
----------
V1=1+-0.03V Vi=10V
----------
----------
V1=1+-0.03V Vi=10V
----------
Information:
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.
If the work described in this Program was performed on the Affected Product under PI7298, Service Letter dated October 30, 1992, DO NOT repeat the work.
This Revised Service Letter replaces the April 28, 1993 Service Letter revised March 1994. Changes have been made to the TERMINATION DATE and Affected Product.
Termination Date
August 31, 1994Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34485)
3208 (9WC1-1093)
3208 (5CD1-9736, 62W1-76455 , 93Z1-10198 )
Parts Stock Remanufactured Fuel Pump Part Numbers
This program applies only to pumps in parts stock with a date code prior to November, 1993 (UUDE). Date codes are in the MM/YY mode with the standard notation of NUMERALKOD.
Parts Needed
Not applicable.
Action Required
Before installing or delivering any of the Affected Product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with:- Fuel Injector Cleaneror- Carburetor/Choke Cleaner4. Allow the components to soak in cleaning solution for 45 minutes. Then, rotate the engine crankshaft to rotate the fuel injection pump and check for free movement of the lever and sleeve (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed.5. If the above procedures do not free the pump assembly, remove the individual pumps from the pump housing, clean them with cleaning solution, and install them back into the housing.6. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.7. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
The inspection of the pump is a .5-hour job. If the pump needs to be cleaned, an additional .5 hour may be claimed. If the individual pumps need to be removed from the pump housing for cleaning, up to an additional 1.5 hours may be claimed.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
If the work described in this Program was performed on the Affected Product under PI7298, Service Letter dated October 30, 1992, DO NOT repeat the work.
This Revised Service Letter replaces the April 28, 1993 Service Letter revised March 1994. Changes have been made to the TERMINATION DATE and Affected Product.
Termination Date
August 31, 1994Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34485)
3208 (9WC1-1093)
3208 (5CD1-9736, 62W1-76455 , 93Z1-10198 )
Parts Stock Remanufactured Fuel Pump Part Numbers
This program applies only to pumps in parts stock with a date code prior to November, 1993 (UUDE). Date codes are in the MM/YY mode with the standard notation of NUMERALKOD.
Parts Needed
Not applicable.
Action Required
Before installing or delivering any of the Affected Product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with:- Fuel Injector Cleaneror- Carburetor/Choke Cleaner4. Allow the components to soak in cleaning solution for 45 minutes. Then, rotate the engine crankshaft to rotate the fuel injection pump and check for free movement of the lever and sleeve (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed.5. If the above procedures do not free the pump assembly, remove the individual pumps from the pump housing, clean them with cleaning solution, and install them back into the housing.6. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.7. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
The inspection of the pump is a .5-hour job. If the pump needs to be cleaned, an additional .5 hour may be claimed. If the individual pumps need to be removed from the pump housing for cleaning, up to an additional 1.5 hours may be claimed.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.