106693-6184 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066936184 8943900470

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106693-6184 1066936184

ISUZU 8943900470 8943900470

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Cross reference number

ZEXEL 106693-6184 1066936184

ISUZU 8943900470 8943900470

Zexel num

Bosch num

Firm num

Name

106693-6184
106693-6185

8943900470 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1TC-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 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-8620

Overflow valve opening pressure kPa 206 172 240

Overflow valve opening pressure kgf/cm2 2.1 1.75 2.45

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.57 3.63

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 11.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108 106 110

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12.5 9.3 15.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108 107 109

Basic *

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 108 104 112

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

Boost compensator adjustment

Pump speed r/min 525 525 525

Rack position R2-1.7

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 525 525 525

Rack position R1-0.2(R 2)

Boost pressure kPa 58.7 58.7 58.7

Boost pressure mmHg 440 440 440

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 3/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1075

Advance angle deg. 1.5 1 2

Load 4/5

Timer adjustment_05

Pump speed r/min 1350

Advance angle deg. 5.5 5 6

Load 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)Boost compensator stroke: BCL
----------
T1=AC30 BCL=1.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Use the hole at R = aa
----------
aa=35mm
----------
a=64deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at rack position = bb, speed = cc and confirm non-injection.
----------
aa=55mm bb=1.5+-0.3mm cc=0r/min
----------
a=14deg+-5deg b=44deg+-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=7deg
----------
a=(50deg)

Information:

Caterpillar: Confidential Yellow
PARTS STOCK ACTION ONLY - CERTAIN 7000 SERIES FUEL INJECTION NOZZLES NEED TO BE REMOVED FROM PARTS STOCK - PI7210 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, TRUCK TEPS
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.
U-105 A-76 AU-71 B-16 E-49 O-69 TT-4 PARTS STOCK ACTION NEEDED 1254 PI7210 Termination Date
August 31, 1989
Problem
Certain 7000 Series fuel injection nozzles may crack and loose their nozzle tips if there is a small indentation or dent in the nozzle between the tip end and the carbon dam.
Action Required
Inspect the following nozzles in parts stock for any small indentations or dents in the tip of the nozzle between the carbon dam groove and the tip end of the nozzle. Remove all nozzles from parts stock that have indentations or dents that are deep enough to be felt with a thumbnail. See the illustration. 8N7003 4W7015 7W7023 8N7005 4W7016 7W7024 8N7006 4W7017 7W7026 4W7018 7W7030 4W7019 7W7031 4W7020 7W7032 4W7021