Information injection-pump assembly
ZEXEL
101491-0230
1014910230
ISUZU
8941279580
8941279580
Rating:
Cross reference number
ZEXEL
101491-0230
1014910230
ISUZU
8941279580
8941279580
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
105780-8140
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.4
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
55
53.4
56.6
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
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
6.7
5.2
8.2
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
R1(10.4)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
55
54
56
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
54.8
53.2
56.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
42.5
40.9
44.1
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.7
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
45.4
43.8
47
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
Z
Rack position
10.1+-0.
5
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
48.9
47.3
50.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1650--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
0.6
Timer adjustment_03
Pump speed
r/min
1800
Advance angle
deg.
3
2.5
3.5
Timer adjustment_04
Pump speed
r/min
1900
Advance angle
deg.
4.5
4
5
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
5
5
5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Torque control stroke: L1
----------
T1=55 L1=1mm
----------
----------
T1=55 L1=1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=5.5deg+-5deg b=38deg+-3deg
----------
----------
a=5.5deg+-5deg b=38deg+-3deg
0000001501 VARIABLE TORQUE CONTROL
N:Pump speed (r/min)
R:Rack position (mm)
Adjusting shim A
Guide screw B
(c) Nut
(d) Nut
(e) nut
Torque control spring adjustment method for model responding to speed droop
[Advice]
Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment.
(1)Temporary idle lever position setting
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
(2)Idling spring adjustment
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
(3)Governor spring setting adjustment
1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor.
2. Set the control lever where it contacts the idle stopper bolt.
3. Increase the speed to Nh2+100 r/min or more.
4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily.
5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E).
6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily.
[Advice]
When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min.
Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change.
(4)Full load position setting
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
(5)Torque control spring adjustment
1. Set the control lever so that it contacts the full speed stopper bolt.
2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily.
3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily.
4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf.
5. Set the speed at Nf-50 r/min.
6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A).
7. After completing shim adjustment, repeat the above adjustment using the two nuts.
8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D).
9. In this condition, increase the speed and confirm that R = 0 can be obtained.
(6)Full speed lever position setting
1. Set the control lever so that it contacts the full speed stopper bolt.
2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily
3. Increase the speed and confirm that the specified rack position Ru can be obtained.
4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix.
5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.'
6. Confirm that the control lever operating angle is within the specifications.
(7)Rack limit adjustment
1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
----------
----------
----------
----------
Timing setting
(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=14deg
----------
a=(100deg)
----------
aa=14deg
----------
a=(100deg)
Information:
REM02-46
Reman
November 2002 REMANUFACTURED FUEL INJECTORS FOR VARIOUS INDUSTRIAL, MACHINE, MARINE AND ON-HIGHWAY TRUCK APPLICATIONS Announcement The Caterpillar Remanufactured Products Group announces the expansion of the remanufactured injector product line to include coverage for various C10, C12, 3176, 3196, 3406E, 3456, C15, C16, and C18 Industrial, Machine, Marine and On-Highway Truck applications. Coverage The addition of these injectors provides dealers with an additional repair option to support various C10, C12, 3176, 3196, 3406E, 3456, C15, C16, and C18 Industrial, Machine, Marine and On-Highway Truck applications where low sulfur fuel is present. Coverage is extensive so please consult your NPR or Reman Cross Reference for exact model coverage. See the matrix on page two for part numbers and cross-reference information. Features And Benefits 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 website and click on Procedures and Policies (listed under Reman Program Information). If you have any questions regarding core return processing, feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928 or use our e-mail address -- reman_core_operations. 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.
PELE0956 CATERPILLAR? ?2002 Caterpillar