Information injection-pump assembly
ZEXEL
101603-7790
1016037790
ISUZU
8943935590
8943935590
Rating:
Cross reference number
ZEXEL
101603-7790
1016037790
ISUZU
8943935590
8943935590
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
3.7
3.65
3.75
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
12.2
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
66.1
64.5
67.7
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
265
265
265
Average injection quantity
mm3/st.
9
7.7
10.3
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(12.2)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
66.1
65.1
67.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.1
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
74.6
71.4
77.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
47.7
44.5
50.9
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
105
105
137
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
2
1.5
2.5
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
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G23
----------
----------
T1=G23
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=53mm
----------
a=11deg+-5deg b=39deg+-3deg
----------
aa=53mm
----------
a=11deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=67mm
----------
a=16deg+-5deg b=29deg+-5deg
----------
aa=67mm
----------
a=16deg+-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=131154-1320 ST=A255 L1=1mm L2=3.7+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131154-1320 ST=A255 L1=1mm L2=3.7+-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)-
----------
aa=10deg
----------
a=(160deg)
----------
aa=10deg
----------
a=(160deg)
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 "PS5331" 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.
Termination Date
October 31, 1998Problem
Some 3116 and 3126 HEUI Engines may have excessive oil consumption as a result of oil leaking past the intensifier piston o-ring inside the injector. Engine oil consumption becomes excessive and may increase rapidly. There are no traditional signs of oil consumption, smoke, blow-by, etc. The engine has no performance problem, has good power and normal exhaust smoke.
The problem seems to be very low frequency and is not batch related.
Affected Product
Model & Identification Number
3116 (8WL1-Up)
3126 (1WM1-Up 4ES1-Up )
Parts Needed
3116 Engines6 - 1162784 Injectors (for 170 Hp)6 - 1166706 Injectors (for 185, 195, 215, 230, 250 and 275 Hp) 3126 Engines6 - 0R4970 Injectors (for 230, 250, 275, 300 and 330 Hp)6 - 0R4972 Injectors (for 175, 190 and 210 Hp)Action Required
See the attached rework procedure.
Service Claim Allowances
Labor Hour Breakdown TK = TopKickMC = Medium Hood ConventionalClaim 1290-500 for an additional 1.6 hours if the repair is made in a motor home chassis, cab type (RV), or bus chassis, cab type (BU).
Parts Disposition
TEPS/MEPS Dealers must return the affected part(s) to their Caterpillar dealer.
Parts must be returned undamaged in the original shipping boxes to:
Caterpillar Inc.
Attn: Michael Mosley - PS5331
8401 N. University
Peoria, Illinois 61615
Injectors must be sealed in a plastic bag to prevent fuel from leaking out during shipment.
A clear, legible copy of the service report in a plastic page protector must be included in the box with the returned injectors. The report must be packaged to arrive free of oil, grease and diesel fuel.
Attach.(1 - Rework Procedure)Rework Procedure
Check to see if PS8826 (Jumper-tube Rework) is to be applied to the affected engine. Perform PS8826 if it has not been performed prior to oil consumption test.
Document the oil consumption for 30 days using the attached Oil Consumption Test Sheet, Form Number 01-081227.
All of the following steps must be followed in order to establish base line data for oil consumption for full warranty reimbursement.
1. Change oil and filter at the beginning of the test to establish base line at normal change interval. Use CG-4 oil and new oil filter. Oil and filter are not claimable under this letter.
2. Refill with the proper amount of oil; 27liters/29 quarts, and 18 liters/19 quarts per the July 1997 Operations Maintenance Manual.3. Inspect for external leaks around the gaskets and the front and rear main seals.4. Inspect the air compressor air tanks for excess oil.5. Inspect the turbo oil drain line for excessive oil indicating seal leak.6. At the completion of
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 "PS5331" 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.
Termination Date
October 31, 1998Problem
Some 3116 and 3126 HEUI Engines may have excessive oil consumption as a result of oil leaking past the intensifier piston o-ring inside the injector. Engine oil consumption becomes excessive and may increase rapidly. There are no traditional signs of oil consumption, smoke, blow-by, etc. The engine has no performance problem, has good power and normal exhaust smoke.
The problem seems to be very low frequency and is not batch related.
Affected Product
Model & Identification Number
3116 (8WL1-Up)
3126 (1WM1-Up 4ES1-Up )
Parts Needed
3116 Engines6 - 1162784 Injectors (for 170 Hp)6 - 1166706 Injectors (for 185, 195, 215, 230, 250 and 275 Hp) 3126 Engines6 - 0R4970 Injectors (for 230, 250, 275, 300 and 330 Hp)6 - 0R4972 Injectors (for 175, 190 and 210 Hp)Action Required
See the attached rework procedure.
Service Claim Allowances
Labor Hour Breakdown TK = TopKickMC = Medium Hood ConventionalClaim 1290-500 for an additional 1.6 hours if the repair is made in a motor home chassis, cab type (RV), or bus chassis, cab type (BU).
Parts Disposition
TEPS/MEPS Dealers must return the affected part(s) to their Caterpillar dealer.
Parts must be returned undamaged in the original shipping boxes to:
Caterpillar Inc.
Attn: Michael Mosley - PS5331
8401 N. University
Peoria, Illinois 61615
Injectors must be sealed in a plastic bag to prevent fuel from leaking out during shipment.
A clear, legible copy of the service report in a plastic page protector must be included in the box with the returned injectors. The report must be packaged to arrive free of oil, grease and diesel fuel.
Attach.(1 - Rework Procedure)Rework Procedure
Check to see if PS8826 (Jumper-tube Rework) is to be applied to the affected engine. Perform PS8826 if it has not been performed prior to oil consumption test.
Document the oil consumption for 30 days using the attached Oil Consumption Test Sheet, Form Number 01-081227.
All of the following steps must be followed in order to establish base line data for oil consumption for full warranty reimbursement.
1. Change oil and filter at the beginning of the test to establish base line at normal change interval. Use CG-4 oil and new oil filter. Oil and filter are not claimable under this letter.
2. Refill with the proper amount of oil; 27liters/29 quarts, and 18 liters/19 quarts per the July 1997 Operations Maintenance Manual.3. Inspect for external leaks around the gaskets and the front and rear main seals.4. Inspect the air compressor air tanks for excess oil.5. Inspect the turbo oil drain line for excessive oil indicating seal leak.6. At the completion of