101603-7860 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037860 8943934620

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7860 1016037860

ISUZU 8943934620 8943934620

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Cross reference number

ZEXEL 101603-7860 1016037860

ISUZU 8943934620 8943934620

Zexel num

Bosch num

Firm num

Name

101603-7860
101603-7861

8943934620 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+0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 90.7 86.7 94.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 61.8 58.6 65

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=G80
----------

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

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11.5)mm Rb=(R1-0.85)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=77.7+-1mm3/st Q2=61.7+-1.6mm3/st

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 only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50780" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode 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. This Revised Service Letter replacesthe April 2, 2004 (Revised April 2004) Service Letter. Changes have beenmade to the Affected Product.TERMINATION DATE
April 30, 2006PROBLEM
Failed injector and wiring harness need to bereplaced on certain C-9 Industrial Engines. The C-9 engine can developan injector misfire due to an open connection at the injector to harnessconnector. This misfire can be diagnosed with standard troubleshootingguide procedures.AFFECTED PRODUCT
Model Identification Number
C9 CLJ1-4259
12H 12500001-40AMZ1-496CBK1-353
330C B1K1-178B2L1-203B4N1-187BTM1-189CGZ1-511CYA1-287D3C1-231JAB1-626JCD1-292JNK1-245KDD1-580MCA1-427MKM1-308GAG1-329RBH1-233
330C L CAP1-1257DKY1-2011HAA1-393
D6R II AEM1-100AFM1-115BLE1-199BLT1-186BMK1-121BNL1-99BPM1-101BPP1-97BPS1-102BRJ1-116
D6R II LGP ACJ1-101ADE1-311BNC1-265BPZ1-142
D6R II XL AAX1-465BMJ1-130BMY1-297BRZ1-115CAD1-143FDT1-141
D6R II XW AEP1-223DAE1-129
470 7651-811
475 7671-824
MT765 AMS1-266
TK711 10100001-00191
TK721 10200001-00191
TK722 10300001-00193
TK732 10400185-00190
627G CEX187-296
637G CEH222-255PARTS NEEDED
Qty
Part Number
Description
1 1567106 Wiring Kit
1 1889865 Harness Assembly
1 2359651 Bolt - Socket
1 2360962 Injector GroupACTION REQUIRED
Replace the single failed injector with the new 2360962 Injector and the1889865 Wiring Harness Assembly. Refer to REHS1809 Special Instructionfor use of the 1567106 Wiring Kit.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
0-35 months 100% 2.0 0 0 0 0
This is a 2?hour job.PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warrantyparts handling.