Information injection-pump assembly
ZEXEL
101603-7600
1016037600
ISUZU
8943969280
8943969280
Rating:
Service parts 101603-7600 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94397-483-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-7600
1016037600
ISUZU
8943969280
8943969280
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
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.2
4.15
4.25
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
69
67.4
70.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.8+-0.5
Pump speed
r/min
265
265
265
Average injection quantity
mm3/st.
18.2
16.9
19.5
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
69
68
70
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
81.7
77.7
85.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
103
103
135
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1270--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1220
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
----------
T1=F46
----------
----------
T1=F46
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=12.5deg+-5deg b=45deg+-3deg
----------
aa=35mm
----------
a=12.5deg+-5deg b=45deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
0000001501 I/P WITH LOAD PLUNGER ADJ
Plunger assembly number: PL (stamping: ST)
1. Adjustment procedures
(1)Insert the pre-stroke adjusting shims L1 for each cylinder.
(2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2)
(3)At basic point A, adjust so that the pre-stroke is L2.
(4)Reconfirm the injection quantity.
----------
PL=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
(5)Pump vertical direction
(6)Direction of rotation
(7)Pointer
(8)Pointer stamping
(9)Timing device stamping
(10)Timing device
(11)Move b deg and stamp both at the same time as shown above.
(12)Outside circumference of timing device
(13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=11deg
----------
a=(150deg) b=1deg15min
----------
aa=11deg
----------
a=(150deg) b=1deg15min
Information:
Caterpillar: Confidential Yellow
PRIORITY - NEW SPRINGS NEED TO BE INSTALLED IN THE UNIT INJECTORS ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PI3 396 - MAILED US, CANADA, CACO, COFA, LIMITED BRAZIL, CFEL, COSA
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.
U-75 A-53 AU-49 B-12.2 E-38.1 O-53.1 PRIORITY parts stock 1290 PI3396 COMPLETION DATE Termination Date
October 31, 1989 April 30, 1990
Problem
The springs in the unit injectors on certain 3606, 3608, 3612, and 3616 Engines may fail and cause unscheduled down time. A spring failure may cause damage to a pushrod or rocker arm.
Affected Product
Model Identification Number 3606 8RB1-293, 296, 297, 314-350, 352, 354, 3608 6MC1-242, 248-250, 251, 253-275, 277-280 5PG1-3 3612 9RC14, 15, 18-47, 52, 53, 57, 58 3616 1PD1-28
Parts Needed
Dealers will need to order parts for this Program. ***** Parts Stock ***** 1 - 7E5404 Spring (1 for each 7C7445 or 7C3854 Injector in the customer or
PRIORITY - NEW SPRINGS NEED TO BE INSTALLED IN THE UNIT INJECTORS ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PI3 396 - MAILED US, CANADA, CACO, COFA, LIMITED BRAZIL, CFEL, COSA
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.
U-75 A-53 AU-49 B-12.2 E-38.1 O-53.1 PRIORITY parts stock 1290 PI3396 COMPLETION DATE Termination Date
October 31, 1989 April 30, 1990
Problem
The springs in the unit injectors on certain 3606, 3608, 3612, and 3616 Engines may fail and cause unscheduled down time. A spring failure may cause damage to a pushrod or rocker arm.
Affected Product
Model Identification Number 3606 8RB1-293, 296, 297, 314-350, 352, 354, 3608 6MC1-242, 248-250, 251, 253-275, 277-280 5PG1-3 3612 9RC14, 15, 18-47, 52, 53, 57, 58 3616 1PD1-28
Parts Needed
Dealers will need to order parts for this Program. ***** Parts Stock ***** 1 - 7E5404 Spring (1 for each 7C7445 or 7C3854 Injector in the customer or