101401-0191 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010191 5156009804


 

Information injection-pump assembly

ZEXEL 101401-0191 1014010191
ISUZU 5156009804 5156009804
101401-0191 INJECTION-PUMP ASSEMBLY
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Service parts 101401-0191 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-8230
3. GOVERNOR 105931-0512
4. SUPPLY PUMP 105220-4882
5. AUTOM. ADVANCE MECHANIS 105622-0730
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4582
11. Nozzle and Holder 5-15300-089-1
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105031-3952
14. NOZZLE 105015-4130
15. NOZZLE SET

Include in #1:

101401-0191 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101401-0191 1014010191
ISUZU 5156009804 5156009804


Zexel num
Bosch num
Firm num
Name
101401-0191 
101401-0193 
 
5156009804  ISUZU
INJECTION-PUMP ASSEMBLY
4BD1 *

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 opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.6 3.55 3.65
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   -
Rack position   11.4
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   70.5 69 72
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   H
Rack position   9.5+-0.5
Pump speed r/min   290 290 290
Average injection quantity mm3/st.   8 6.7 9.3
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   11.4
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   70.5 69.5 71.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   11+-0.5
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   70.7 67.5 73.9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   11.3+-0. 5
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   76 72.8 79.2
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   11.15+-0 .5
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   53.5 50.3 56.7
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   11.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   55 51 59
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   I
Rack position   R2(14.5+ -0.5)
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   95 95 103
Fixing the rack   *
Timer adjustment
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1350
Advance angle deg.   1.1
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   1.6
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-0191
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=47
----------

Speed control lever angle

Test data 101401-0191
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=30deg+-5deg b=41deg+-3deg

Timing setting

Test data 101401-0191
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(100deg)




Information:


Information Release Memo REM03-29
Reman
October 2003 APPEARANCE CHANGE ON REMAN 3126B AND 3126E HEUI? INJECTORS Announcement The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat Reman 3126B and 3126E HEUI Injectors effective 10/01/03. In order to improve appearance and salvage of injector stator covers, Cat Reman will begin using stator cover marking plates on selected 3126 HEUI injectors. Currently, Cat Reman must remove the old part number and codes from the stator cover by grinding. This process can only be done once and often opens porosity in the stator causing scrap or unacceptable appearance. Effective 9/1/03 Cat Reman will begin using a disposable marking plate. See the picture below. The cover and stator are not serviced separately; the picture is for clarity only. This change will not alter fit or performance in any way. Part numbers affected are 0R1050, 0R9348, 0R9349, 0R9350, 10R0781, 10R0782, and 10R1257. Features And Benefits Cat Remanufactured injectors offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price. Features
All critical engineering changes and updates included
Worldwide availability through Caterpillar? parts distribution system
Backed by Cat warranty Benefits
Improved reliability and performance
Customer access regardless of location
Consistent support
Core Acceptance Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Full core credit is issued when the core is complete, fully assembled, and has an acceptable part number. Consult your Core Acceptance Guide for complete details. Warranty Please consult the appropriate warranty statement for your area. Core Management Please refer to the Caterpillar Core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail. For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman Dealer website https://reman.cat.com If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0235 CATERPILLAR?

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