Information injection-pump assembly
ZEXEL
101603-7800
1016037800
ISUZU
8943935840
8943935840
Rating:
Cross reference number
ZEXEL
101603-7800
1016037800
ISUZU
8943935840
8943935840
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.
66.9
65.3
68.5
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(11.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
66.9
65.9
67.9
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.
78.5
74.5
82.5
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.
49.7
46.5
52.9
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
99
99
131
Fixing the lever
*
Timer adjustment
Pump speed
r/min
(1220)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
1.3
0.8
1.8
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=G22
----------
----------
T1=G22
----------
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=38deg+-3deg
----------
aa=53mm
----------
a=11deg+-5deg b=38deg+-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=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) b=1deg
----------
aa=11deg bb=1deg
----------
a=(150deg) b=1deg
Information:
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS9436" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
March 31, 1999Problem
Engines may experience ingress of coolant to the fuel system or vice versa due to the degradation of the sleeve seal-o-rings and the unit injector seal-o-rings. The contamination of coolant into the fuel system affects engine performance and can cause injector seizure. Contamination of fuel in the cooling system may reduce cooling performance.
Affected Product
Model & Identification Number
The work outlined in this program is to occur once only for the following engines with a minimum of 300,000 liters of fuel burned. In most applications this generally corresponds to:
*Every 300,000 kms of engine life for B-Triple and Triple Road Trains.*Every 450,000 kms of engine life for B-Double and Double Road Trains.*Every 600,000 kms of engine life for Single Trailers.3406E (5EK1-Up 6TS1-Up 1LW1-Up 5DS1-Up )
Parts Needed
6 - 9X7317 SEAL-O RING (Lower Seal-0-ring of unit Injector),6 - 9X7418 SEAL-O RING (Upper Seal-0-ring of Unit Injector),6 - 9X7419 SEAL-O RING (Mddle Seal-0-ring of Unit Injector),6 - 9X7430 SEAL-O-RING (Upper Seat-0-ring of unit Injector Sleeve),12- 9X7431 SEAL-O-RING (Lower Seal-0-ring of unit Injector Sleeve, two per sleeve),Action Required
See the attached procedure.
Service Claim Allowances
This job varies by cab type.
*See labor breakdowns. Labor Hours By Cab Type Parts Disposition
Please return seal-o-rings packaged in plastic bags, with relevant history of the truck and engine, to:
Steve Keenan,
Application and Service Engineer-
Caterpillar of Australia.
Private Mailbag 4.
Tuilamarine. 3043.
Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
(1-Rework Procedure)Rework Procedure
1. Refer to attached parts book drawings.2. Obtain an ECM print-out from the Truck. Retain this print-out.3. Remove set of unit injectors. (Code 1290-010: refer p.109 of TRG for 3406E on highway truck engines;4. Drain and collect coolant.5. Remove and install set of unit injector sleeves (Code 1713-010: refer p. 111 of TRG).6. Replace injector body seals and sleeve seals. Return seals only as per parts disposition.7. Install set of unit injectors.8. Refill with coolant.9. Install set of unit injector sleeves.
Illustration 1.
Illustration 2.
Termination Date
March 31, 1999Problem
Engines may experience ingress of coolant to the fuel system or vice versa due to the degradation of the sleeve seal-o-rings and the unit injector seal-o-rings. The contamination of coolant into the fuel system affects engine performance and can cause injector seizure. Contamination of fuel in the cooling system may reduce cooling performance.
Affected Product
Model & Identification Number
The work outlined in this program is to occur once only for the following engines with a minimum of 300,000 liters of fuel burned. In most applications this generally corresponds to:
*Every 300,000 kms of engine life for B-Triple and Triple Road Trains.*Every 450,000 kms of engine life for B-Double and Double Road Trains.*Every 600,000 kms of engine life for Single Trailers.3406E (5EK1-Up 6TS1-Up 1LW1-Up 5DS1-Up )
Parts Needed
6 - 9X7317 SEAL-O RING (Lower Seal-0-ring of unit Injector),6 - 9X7418 SEAL-O RING (Upper Seal-0-ring of Unit Injector),6 - 9X7419 SEAL-O RING (Mddle Seal-0-ring of Unit Injector),6 - 9X7430 SEAL-O-RING (Upper Seat-0-ring of unit Injector Sleeve),12- 9X7431 SEAL-O-RING (Lower Seal-0-ring of unit Injector Sleeve, two per sleeve),Action Required
See the attached procedure.
Service Claim Allowances
This job varies by cab type.
*See labor breakdowns. Labor Hours By Cab Type Parts Disposition
Please return seal-o-rings packaged in plastic bags, with relevant history of the truck and engine, to:
Steve Keenan,
Application and Service Engineer-
Caterpillar of Australia.
Private Mailbag 4.
Tuilamarine. 3043.
Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
(1-Rework Procedure)Rework Procedure
1. Refer to attached parts book drawings.2. Obtain an ECM print-out from the Truck. Retain this print-out.3. Remove set of unit injectors. (Code 1290-010: refer p.109 of TRG for 3406E on highway truck engines;4. Drain and collect coolant.5. Remove and install set of unit injector sleeves (Code 1713-010: refer p. 111 of TRG).6. Replace injector body seals and sleeve seals. Return seals only as per parts disposition.7. Install set of unit injectors.8. Refill with coolant.9. Install set of unit injector sleeves.
Illustration 1.
Illustration 2.