Information injection-pump assembly
BOSCH
F 019 Z10 504
f019z10504
ZEXEL
101603-7720
1016037720
ISUZU
8943933421
8943933421
Rating:
Service parts 101603-7720 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94397-483-3
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Include in #1:
101603-7720
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-6723
as _
Cross reference number
BOSCH
F 019 Z10 504
f019z10504
ZEXEL
101603-7720
1016037720
ISUZU
8943933421
8943933421
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
11.2
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.5
71.9
75.1
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
9.5+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
8.3
7
9.6
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(11.2)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.5
72.5
74.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
84.6
80.6
88.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
55.3
52.1
58.5
Fixing the lever
*
Injection quantity adjustment_06
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
1210--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1160
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G22
----------
----------
T1=G22
----------
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=11deg+-5deg b=(39deg)+-3deg
----------
aa=35mm
----------
a=11deg+-5deg b=(39deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=62.5mm
----------
a=12.5deg+-5deg b=29deg+-5deg
----------
aa=62.5mm
----------
a=12.5deg+-5deg b=29deg+-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)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 bb=1deg
----------
a=(150deg)
----------
aa=11deg bb=1deg
----------
a=(150deg)
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.
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 "PS0902" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the November 29, 1995 (Revised December 1995) Service Letter. Changes have been made to the Parts Needed and Service Claim Allowances.
This Revised Service Letter replaces the November 29, 1995 (Revised January 1996) Service Letter. Changes have been made to the Action Required.
Termination Date
November 30, 1996Problem
Some 3406C Engines may have white smoke at start up. The problem is related to 8PN Engines that were built using the 1007567 and 1214353 Nozzles.
Affected Product
Model & Identification Number
3406C (8PN1-5802) (425 hp) 8PN1-5985 ) (350 hp)
Parts Needed
6 - 0R8289 Nozzle Assembly (for 350 hp)6 - 0R8290 Nozzle Assembly (for 425 hp)Action Required
1. Remove the 1214353 Nozzles and install the 0R8289 Nozzles on engines with 350 hp.2. Remove the 1007567 Nozzles and install the 0R8290 Nozzles on engines with 425 hp.Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
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 "PS0902" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the November 29, 1995 (Revised December 1995) Service Letter. Changes have been made to the Parts Needed and Service Claim Allowances.
This Revised Service Letter replaces the November 29, 1995 (Revised January 1996) Service Letter. Changes have been made to the Action Required.
Termination Date
November 30, 1996Problem
Some 3406C Engines may have white smoke at start up. The problem is related to 8PN Engines that were built using the 1007567 and 1214353 Nozzles.
Affected Product
Model & Identification Number
3406C (8PN1-5802) (425 hp) 8PN1-5985 ) (350 hp)
Parts Needed
6 - 0R8289 Nozzle Assembly (for 350 hp)6 - 0R8290 Nozzle Assembly (for 425 hp)Action Required
1. Remove the 1214353 Nozzles and install the 0R8289 Nozzles on engines with 350 hp.2. Remove the 1007567 Nozzles and install the 0R8290 Nozzles on engines with 425 hp.Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.