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Product: GEN SET ENGINE


Model: 3516 GEN SET ENGINE 25Z
Configuration: 3516 Generator Set Engine 25Z02189-UP

Service Magazine
1989/10/02
Media Number -SEBD1985-00 Publication Date -02/10/1989 Date Updated -02/10/1989

Fuel Injector Reference For 3500 Family Of Engines{1290}


SMCS - 1290

3500 Family Of Engines;


D11N, 776B Tractors;
777B, 785, 789 Trucks

Reference: Service Magazine; June 1, 1987; Page 17; "Fuel Injector Trim Bolt," on all 3500 and 3600
Families of Engines. Service Magazine; November 21, 1988; Page 8; "One Piece Tappet Used In 11 mm
Fuel Injectors," in the 3500 Family Of Engines. Service Magazine; August 28, 1989; "New Fuel
Injectors Available For Parts Service," in the 3500 Family Of Engines.

This article replaces the January 19, 1987 Service Magazine article "Fuel Injector Reference For 3500
Family Of Engines."

The 3500 Family of Engines has a number of different fuel injector assemblies for different operating
speeds, power ratings, and product improvements. This has caused some confusion. This article will
summarize:

...all of the injectors that have been used.

...the differences between the injectors.

...how to identify different injectors.

...which injectors are used for various applications, operating rpm, and power ratings.

All injectors for 3500 Family of Engines are one of two types. For purposes of this article we will refer
to then as Type 1 and Type 2. Type 1 injectors have 10.7 mm (.42") diameter plungers. Type 2 injectors
have 11.0 mm (.43") diameter plungers.

There are other basic design differences between the two types. Refer to Illustration 1 and 2 for
examples of Type 1 injectors, and Illustration 3 for an example of a Type 2 injector. When not installed,
injectors may be identified by the injector case. Type 1 injectors use a one piece case that encloses the
plunger and barrel assembly as well as the nozzle assembly. Type 2 injectors use a case that encloses
only the plunger and barrel assembly and a separate cone that encloses the nozzle capsule. When

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installed in the cylinder head, Type 2 injectors can be identified by the trim bolt as shown in Illustration
4. This trim bolt must not be adjusted (see Service Magazine; June 1, 1987; Page 17; "Fuel Injector Trim
Bolt"). Newer Type 2 injectors may also be identified by the part number etched on the tappet. Type 1
injectors have no trim bolt. Older Type 2 injectors may also be identified by a two piece tappet as shown
in Illustration 5 (see Service Magazine; November 21, 1988; Page 8; "One Piece Tappet Used In 11 mm
Fuel Injectors").

Illustration 1. Type 1 injector.

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Illustration 2. Type 1 injector tip has identification information which shows orifice diameter in mm, number of orifices, and
spray angle.

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Illustration 3. Type 2 injector.

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Illustration 4. Location of trim bolt on Type 2 injectors.

Illustration 5. Two piece tappet.

The plunger scroll type give the injector its most unique characteristics. The characteristics follow:

... SINGLE SCROLL INJECTORS do not have variable injection timing (time when injection starts).
The beginning of injection is fixed as the plunger rotates from the low to full fuel position.

... DOUBLE SCROLL INJECTORS have variable injection timing. The beginning of injection
advances as the plunger rotates from the low to full fuel position.

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... TIMING RETARD INJECTORS have variable injection timing at lower engine loads and constant
injection timing at higher engine loads. The beginning of injection advances as the plunger rotates from
the low to mid fuel position, but does not change from mid to full fuel position. In essence, the timing
retard injector acts a double scroll at lower fuel position and then as a single scroll injector at higher fuel
positions.

NOTE: Injectors which have either different tip orifice diameters or a different plunger design will have
different fuel delivery characteristics. Injectors that vary in these characteristics can not be used as a
mixed set in an engine.

The charts show differences between part numbers and engine serial number ranges for the injectors.
The color code referred to in the chart corresponds to the color of a small amount of paint applied to the
top of the follower.

Chart A contains Type 1 injector information (Type 2 injectors that are direct field replacements are also
shown). Chart B contains Type 2 injector information. The Engine Fuel Specifications Microfiche can
also be used to identify the type of injector assembly used.

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Copyright 1993 - 2006 Caterpillar Inc. Wed Jan 11 13:59:51 UTC+0700 2006
All Rights Reserved.
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