101401-0261 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010261 5156012172


 

Information injection-pump assembly

ZEXEL 101401-0261 1014010261
ISUZU 5156012172 5156012172
101401-0261 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101401-0261 1014010261
ISUZU 5156012172 5156012172


Zexel num
Bosch num
Firm num
Name
101401-0261 
 
5156012172  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   131424-0620
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   A
Rack position   11.3
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   68.8 67.3 70.3
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   9.6+-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   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   11.3+-0. 5
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   68.8 67.8 69.8
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   10.95+-0 .5
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   68.6 67 70.2
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   11.15+-0 .5
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   72.5 70.9 74.1
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   11.05+-0 .5
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   50.3 48.7 51.9
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   11.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   51.9 49.9 53.9
Fixing the lever   *
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 101401-0261
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=36 RAL=14.4+0.2mm
----------

Speed control lever angle

Test data 101401-0261
F:Full speed I:Idle
----------

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

Timing setting

Test data 101401-0261
(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:


Table Continued:
Engine Model Reman Kit Part Number Kit Consist New Equivalent Part Number Part Description Qty per Kit Date Available
C15 ACERT 10R9236 10R1273 2490709 INJECTOR GP-FUEL 6 1-Jul-09
1R0749 1R0749 FILTER AS.-FUEL 1
8S9191 8S9191 BOLT 6
Features and Benefits
Cat? Remanufactured Components offer your customers excellent value. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of Cat Reman Injector Kits. Cat Remanufactured Components provide immediate, off-the-shelf availability at a fraction of the new price.
Cat Reman Injector Kits offer many benefits. Customers save time by installing all injectors in one service call instead of having multiple service calls to install injectors one or two at a time. Customers save money by eliminating redundant labor costs and down time due to multiple service calls to replace injectors only when they fail. Cat Reman Injector Kits also offer the convenience of delivering all components necessary to do injector replacements in one box under one part number and additionally include a replacement secondary fuel filter.
In addition to saving time and money, customers who install a Cat Reman Injector Kit will maximize their engine performance, optimize fuel economy and restore the operation of their 3126B, C-12, and C15 ACERTTM engines for years to come.
Features Benefits
All critical engineering changes and updates included Improved reliability and performance
Worldwide availability through Cat parts distribution system Customer access regardless of location
Backed by Cat parts warranty Consistent support
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured Fuel Injectors is simple, visual, and requires no special tools. Consult the Unit Injectors ? Electronic Core Acceptance Criteria SELD0226 for complete details. The purchase of a Reman Kit establishes core entitlements at the consist part level quantity. For example, purchase of a kit of six Reman Injectors establishes six individual core injector entitlements.
Warranty
Please consult the appropriate Cat? parts warranty statement for your area.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for your assigned Core Help Line Contact Information; the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as Policy and Core Management SELD0122 -10, "Core Management Systems and Operations Procedures SELD0040-14, "Reman Core Return Packaging Instructions And Guidelines SELD0300-00 and "Shipping Instructions" SELD0039-14.
If you have any questions regarding Reman Core Management or Core Management Information Systems (CMIS2), feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928. Outside the US please refer to the Core section of the Reman website for appropriate contact information for your region.
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