Information injection-pump assembly
ZEXEL
101603-7891
1016037891
ISUZU
8943934771
8943934771
Rating:
Service parts 101603-7891 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94394-787-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-7891
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-6910
as _
Cross reference number
ZEXEL
101603-7891
1016037891
ISUZU
8943934771
8943934771
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
3.6
3.55
3.65
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.
73.4
71.8
75
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(11.2)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.4
72.4
74.4
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.
83.7
79.7
87.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1(11.2)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
57.5
54.3
60.7
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
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
3
2.5
3.5
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.
(3)RACK LIMIT
----------
T1=G95
----------
----------
T1=G95
----------
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=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
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)
----------
aa=14deg
----------
a=(150deg)
Information:
Later Governors Any adjustment to the governor must be made only by a person approved by Caterpillar or by a Caterpillar Dealer.(1) Torque for nut ... 12 4 N m (9 3 lb.ft.).(2) 6N8793 Spring: Length under test force ... 19.05 mm (.750 in.)Test force ... 2.00 0.13 N (.45 .03 lb.)Free length after test ... 41.9 mm (1.65 in.)Outside diameter ... 9.40 mm (.370 in.)(3) Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.(4) 9L6449 Spring for the governor: Color code ... one green stripe, one brown stripePut force on spring of ... 22 N (5 lb.)Then add more force to make spring shorter by ... 22.86 mm (.900 in.)Total test force ... 86.6 1.8 N (19.4 .4 lb.)Free length after test ... 56.9 1 mm (2.24 .04 in.)Outside diameter ... 35.23 mm (1.387 in.)
Install Spring Washers As Shown(4) 9L6448 Spring for the governor: Color code ... one green stripe, one yellow stripePut force on spring of ... 22.24 N (4.00 lb.)Then add more force to make spring shorter by: ... 22.86 mm (.900 in.)Total test force ... 73.00 1.50 N (16.60 .30 lb.)Free length after test ... 56.9 0.8 mm (2.24 .03 in.)Outside diameter ... 35.3 mm (1.39 in.)(5) 9M6303 Spring: Length under test force ... 4.57 mm (1.80 in.)Test force ... 45 4 N (10 1 lb.)Free length after test ... 8.74 mm (.344 in.)Outside diameter ... 12.19 mm (.480 in.)(6) Diameter of the outer surface of the cylinder (new) ... 38.100 0.013 mm (1.5000 .0005 in.)Bore in the gear (new) ... 38.151 0.013 mm (1.5020 .0005 in.).(7) Put marks in alignment on pinion-stop and gear before installing dowel.(8) Bore in the bearing (new) ... 22.263 0.038 mm (.8765 .0015 in.)Diameter of the gear at the hub (new) ... 22.187 0.013 mm (.8735 .0005 in.).
Earlier Governors
Governor Plate(9) Distance from the face of the plate to the bearing for the governor drive assembly ... 0.51 0.25 mm (.020 .010 in.).(10) Dowel installation: Angle A must be ... 54 10°Dimension B must be ... 7.9 0.5 mm (.31 .02 in.)(11) Install dowels to get a dimension of ... 5.6 0.5 mm (.22 .02 in.).
Control Shaft Bearings(12) Bore in the governor control shaft bearings (after assembly) ... 15.761 0.038 mm (.6205 .0015 in.) Diameter of the governor control shaft (new) ... 15.720 0.008 mm (.6189 .0003 in.)(13) Distance between the bearings for the governor control shaft ... 60.58 0.13 mm (2.385 .005 in.)(14) Distance from the face of the housing to the end of the bearing for the governor control shaft ... 43.38 0.15 mm (1.708 .006 in.)
Shutoff Shaft Bearings(15) Bore in the shutoff shaft bearing (new) ... 12.713 0.013 mm (.5005 .0005 in.) Diameter of the shutoff shaft (new)