Information injection-pump assembly
ZEXEL
106861-1414
1068611414
ISUZU
1156020372
1156020372
Rating:
Service parts 106861-1414 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-163-2
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106861-1414
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106861-1414
1068611414
ISUZU
1156020372
1156020372
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve (drive side)
134424-3720
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
kgf/cm2
2.6
2.25
2.95
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
1-8-7-3-
6-5-4-2
Pre-stroke
mm
4
3.97
4.03
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
7
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
89.1
87.1
91.1
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
78.8
77.3
80.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
5+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8
6.6
9.4
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
900+50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
4.1
3.6
4.6
Timer adjustment_03
Pump speed
r/min
(1200)
Advance angle
deg.
6.5
6.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Damper spring setting
(2)Deliver with positive torque control spring not operating
(3)Excess fuel setting for starting: SXL
----------
SXL=8.5+-0.1mm
----------
----------
SXL=8.5+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=6.5deg+-5deg
----------
----------
a=6.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=10deg+-5deg b=30deg+-3deg
----------
aa=35mm
----------
a=10deg+-5deg b=30deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(170deg)
----------
aa=12deg
----------
a=(170deg)
Information:
ACTION REQUIRED
1. Refer to Special Instruction, REHS5023, "Replacing the Fuel Injection Pump on Certain C9.3 Engines". Replace the existing 375-5244 or early production 379-0150 common rail fuel injection pump with the new production 379-0150 common rail fuel injection pump and new gasket 6V-8260. Install a new 356-5214 fuel line from the common rail fuel injection pump to the fuel rail.
2. Refer to C9.3 Disassembly and Assembly, KENR8149 "Engines for Caterpillar Built Machines". Replace the prior 362-0770 Pressure Relief Valve with 415-4991 Pressure Relief Valve, and 228-7102 O-ring.
3. Refer to Service Magazine, SEPD1818, "An Improved Fuel Injection Pump Group Is Used on Certain C9.3 Machine Engines", in order to record the common rail fuel injection pump serial number. This serial number must be entered into the containment service letter claim story.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-4000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-6000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 12.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-4000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-6000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 16.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.