106991-1120 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069911120 1156025303

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106991-1120 1069911120

ISUZU 1156025303 1156025303

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Buy INJECTION-PUMP ASSEMBLY 106991-1120 zexel genuine, new aftermarket engine parts with delivery

Service parts 106991-1120 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9070

3. GOVERNOR 105488-1480

4. SUPPLY PUMP 105237-1940

5. AUTOM. ADVANCE MECHANIS 105687-0280

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7851

11. Nozzle and Holder 1-15300-204-1

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-8200

15. NOZZLE SET

Include in #1:

106991-1120 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106991-1120 1069911120

ISUZU 1156025303 1156025303

Zexel num

Bosch num

Firm num

Name

106991-1120
106991-1121

1156025303 ISUZU

INJECTION-PUMP ASSEMBLY
10PD1-S * K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve (drive side) 134424-4020

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-6- 5-4-3-10 -9-2

Pre-stroke mm 4.2 4.17 4.23

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 110 108.5 111.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 111.6 109.6 113.6

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 117.4 115.4 119.4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 4.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.8 7.5 10.1

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 800+-30

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Damper spring setting (3)Variable speed specification: idling adjustment (4)Main spring setting
----------

----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=150mm
----------
a=6deg+-5deg b=(21deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=40mm
----------
a=10deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=60deg+-5deg b=73deg+-5deg

0000001501 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------

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 (set timing) (4)-
----------
aa=8deg
----------
a=(180deg)

Information:

This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50780" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe April 2, 2004 (Revised April 2004) Service Letter. Changes have beenmade to the Affected Product.TERMINATION DATE
April 30, 2006PROBLEM
Failed injector and wiring harness need to bereplaced on certain C-9 Industrial Engines. The C-9 engine can developan injector misfire due to an open connection at the injector to harnessconnector. This misfire can be diagnosed with standard troubleshootingguide procedures.AFFECTED PRODUCT
Model Identification Number
C9 CLJ1-4259
12H 12500001-40AMZ1-496CBK1-353
330C B1K1-178B2L1-203B4N1-187BTM1-189CGZ1-511CYA1-287D3C1-231JAB1-626JCD1-292JNK1-245KDD1-580MCA1-427MKM1-308GAG1-329RBH1-233
330C L CAP1-1257DKY1-2011HAA1-393
D6R II AEM1-100AFM1-115BLE1-199BLT1-186BMK1-121BNL1-99BPM1-101BPP1-97BPS1-102BRJ1-116
D6R II LGP ACJ1-101ADE1-311BNC1-265BPZ1-142
D6R II XL AAX1-465BMJ1-130BMY1-297BRZ1-115CAD1-143FDT1-141
D6R II XW AEP1-223DAE1-129
470 7651-811
475 7671-824
MT765 AMS1-266
TK711 10100001-00191
TK721 10200001-00191
TK722 10300001-00193
TK732 10400185-00190
627G CEX187-296
637G CEH222-255PARTS NEEDED
Qty
Part Number
Description
1 1567106 Wiring Kit
1 1889865 Harness Assembly
1 2359651 Bolt - Socket
1 2360962 Injector GroupACTION REQUIRED
Replace the single failed injector with the new 2360962 Injector and the1889865 Wiring Harness Assembly. Refer to REHS1809 Special Instructionfor use of the 1567106 Wiring Kit.SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-5000
0-35 months 100% 2.0 0 0 0 0
This is a 2?hour job.PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warrantyparts handling.