101603-7831 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037831 8943934591

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7831 1016037831

ISUZU 8943934591 8943934591

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Service parts 101603-7831 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6080

3. GOVERNOR 105931-8771

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0810

6. COUPLING PLATE 105661-0781

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5702

11. Nozzle and Holder 8-94394-787-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1090

15. NOZZLE SET

Include in #1:

101492-0571 as _

101603-7831 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7831 1016037831

ISUZU 8943934591 8943934591

Zexel num

Bosch num

Firm num

Name

101603-7831
101603-7832

8943934591 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.7 76.1 79.3

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. 8.8 7.5 10.1

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(11.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.7 76.7 78.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 93.3 89.3 97.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 60.9 57.7 64.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 96 96 104

Fixing the lever *

Timer adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4 3.5 4.5

Remarks
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. (3)RACK LIMIT
----------
T1=H09
----------

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=36deg+-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

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=14deg
----------
a=(150deg)

Information:

This Program can be administered aftera failure occurs. The decision whether to apply the Program is made bythe dealer. When reporting the repair, use "PS50440" as the Part numberand "7755" as the Group Number and use 135579 DTF Code. Use "96" as theWarranty Claim Description Code 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. Dealer and District are responsible fordetermining eligibility. Engine installations that are known to have airentry into fuel supply are not eligible for this program.TERMINATION DATE
April 30, 2003PROBLEM
The fuel injector tip may fail on certain 3500BMarine and Genset enginesAFFECTED PRODUCT
Group1
Model Identification Number
3508B 2HW125-1601TW249-2713DW153-161
3512B 4AW329-4282GW234-277
3512B M/AUX 1PW355-361
3516B 1NW122-1342FW183-2123CW236-242
Group2
Model Identification Number
3508B 2BM139-151
3512B 7HM207-224
3516B 8CN170-180
Group3
Model Identification Number
3512B 4TN207-3118EM317-352
3516B 8KN368-4159AN175-201
Group4
Model Identification Number
3508B 7SM229-328
Group5
Model Identification Number
3508B 3DM157-206 PARTS NEEDED
Group 1* - 0R9944
* 8 for 3508 Engines (2HW125-160, 1TW249-271, 3DW153-161)
12 for 3512 Engines (4AW329-428, 2GW234-277, 1PW355-361)
16 for 3516 Engines (1NW122-134, 2FW183-212, 3CW236-242)Group 2* - 0R8691
* 8 for 3508 Engines (2BM139-151)
12 for 3512 Engines (7HM207-224)
16 for 3516 Engines (8CN170-180)Group 3* - 0R8688
* 12 for 3508 Engines (4TN207-311, 8EM317-352)
16 for 3512 Engines (8KN368-415, 9AN175-201)Group 4* - 0R8688 ?OR- 0R8690
* 8 for 3508 Engines (7SM229-328)Group 5* - 0R8690
* 8 for 3508 Engines (3DM157-206)ACTION REQUIRED
Replace all injectors and resultant damage, perstandard repair procedures (SENR6564-04 for injector R&I).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 hrs(0-24 mos) 100% 100% 0 0 0 0
5001-10000 hrs(24-48 mos) 33.3% 50% 0 0 50% 50%
NOTE : Maximum allowable labor for injectorreplacement is 1 hour plus 0.5 hours per injector. Use labor times listedin the Time Requirement Guide for replacing the resultant damage.PARTS DISPOSITION
***** North American and Canadian Dealers*****Return Complete Injector Sets to:Caterpillar Inc.Attn: Fergal O?Shea
Service Claims Room (PS50440)
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on
warranty parts handling.