Information injection-pump assembly
ZEXEL
106693-6196
1066936196
ISUZU
8943900481
8943900481
Rating:
Service parts 106693-6196 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94390-049-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}/22.1{225}
15.
NOZZLE SET
Include in #1:
106693-6196
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106693-6196
1066936196
ISUZU
8943900481
8943900481
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
105780-8250
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
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
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
3.57
3.63
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
101.5
99.5
103.5
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(11.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
101.5
100.5
102.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.6
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
92.5
88.5
96.5
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R2-1.3
Boost pressure
kPa
12
10.7
13.3
Boost pressure
mmHg
90
80
100
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R1-0.15(
R2)
Boost pressure
kPa
50.7
50.7
50.7
Boost pressure
mmHg
380
380
380
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Load
3/5
Remarks
Start
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.
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
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=AC45 BCL=1.3+-0.1mm
----------
----------
T1=AC45 BCL=1.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=35mm
----------
a=64deg+-5deg b=(36.5deg)+-3deg
----------
aa=35mm
----------
a=64deg+-5deg b=(36.5deg)+-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
----------
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)
----------
aa=7deg
----------
a=(50deg)
Information:
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.
This Program must be administered as soon as possible. When reporting the repair, use "PI3841" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3841" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
July 31, 1996Termination Date
January 31, 1997Problem
Shot peening on some 3500 Diesel Cylinder Heads extends too far into the injector bore. This may cause the top injector o-ring to be cut or torn on installation.
Affected Product
Model & Identification Number
777C (4XJ844, 4XJ846-872, 4XJ879, 4XJ883, 4XJ885)
785B (6HK483-489)
789B (7EK355-364, 7EK367)
793B (1HL359-367)
3512 (1LM67-73 4WJ649 )
3512B (8RM126-129 4TN40 )
3516 (4XF605, 4XF606 5SJ392-397 2PK918 )
3516B (8CN134 8KN69 , 8KN70 7RN253-259 )
Parts Needed
Dealers will need to order parts for this Program.
1 - 8J8725 Seal-O-Ring (per cylinder)1 - 8T7767 Wheel-Level (per engine)1 - 8T7768 Mandrel (per engine)Action Required
1. Remove the valve cover, rocker arm assembly and fuel injector.2. Inspect the top injector o-ring seal for damage. If damaged, polish the upper injector bore area using an 8T7767 Polishing Wheel and an 8T7768 Mandrel. Install a new 8J8725 O-Ring Seal on each injector.3. Install the injector using clean engine oil in the injector bore and on the o-rings.4. Install rocker arm assembly and reset valves and injector. Install valve covers.Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)Copy Of Owner Notification For U.s. And Canadian Owners
This Program must be administered as soon as possible. When reporting the repair, use "PI3841" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3841" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
July 31, 1996Termination Date
January 31, 1997Problem
Shot peening on some 3500 Diesel Cylinder Heads extends too far into the injector bore. This may cause the top injector o-ring to be cut or torn on installation.
Affected Product
Model & Identification Number
777C (4XJ844, 4XJ846-872, 4XJ879, 4XJ883, 4XJ885)
785B (6HK483-489)
789B (7EK355-364, 7EK367)
793B (1HL359-367)
3512 (1LM67-73 4WJ649 )
3512B (8RM126-129 4TN40 )
3516 (4XF605, 4XF606 5SJ392-397 2PK918 )
3516B (8CN134 8KN69 , 8KN70 7RN253-259 )
Parts Needed
Dealers will need to order parts for this Program.
1 - 8J8725 Seal-O-Ring (per cylinder)1 - 8T7767 Wheel-Level (per engine)1 - 8T7768 Mandrel (per engine)Action Required
1. Remove the valve cover, rocker arm assembly and fuel injector.2. Inspect the top injector o-ring seal for damage. If damaged, polish the upper injector bore area using an 8T7767 Polishing Wheel and an 8T7768 Mandrel. Install a new 8J8725 O-Ring Seal on each injector.3. Install the injector using clean engine oil in the injector bore and on the o-rings.4. Install rocker arm assembly and reset valves and injector. Install valve covers.Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)Copy Of Owner Notification For U.s. And Canadian Owners