101491-0265 ZEXEL 9 400 610 154 BOSCH INJECTION-PUMP ASSEMBLY 9400610154 1014910265 8941390196

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 154 9400610154

ZEXEL 101491-0265 1014910265

ISUZU 8941390196 8941390196

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Buy INJECTION-PUMP ASSEMBLY 101491-0265 zexel genuine, new aftermarket engine parts with delivery

Service parts 101491-0265 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8510

3. GOVERNOR 105931-5450

4. SUPPLY PUMP 105210-4630

5. AUTOM. ADVANCE MECHANIS 105622-1220

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6090

11. Nozzle and Holder 8-94114-604-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3940

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101491-0265 as INJECTION-PUMP ASSEMBLY

101492-3200 as _

Cross reference number

BOSCH 9 400 610 154 9400610154

ZEXEL 101491-0265 1014910265

ISUZU 8941390196 8941390196

Zexel num

Bosch num

Firm num

Name

101491-0265

9 400 610 154

8941390196 ISUZU

INJECTION-PUMP ASSEMBLY
4BC2 K 14BC INJECTION PUMP ASSY PE4A,5A, PE

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

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 3.4 3.35 3.45

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 10.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.2 47.6 50.8

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 9.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 8 11

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 R1(10.2)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.2 48.2 50.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 46.5 43.3 49.7

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. 39.8 36.6 43

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. 38.6 34.6 42.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 57.5 52.5 62.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1650--

Advance angle deg. 0 0 0

Remarks
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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A49
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=5.5deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=45deg+-5deg b=40deg+-5deg

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=16deg
----------
a=(100deg)

Information:

REM05-08
CAT® Reman
February 2005 APPEARANCE CHANGE TO CAT® REMAN DIFN NOZZLES Announcement The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat Reman DIFN nozzles effective 02/04/05. In order to improve the salvage of DIFN nozzles, Cat Reman will begin using bodies for a third life on select DIFN nozzels. The current process allows for only one use. Effective on 02/04/05 they will begin machining the nozzle bodies to allow for a new tip to be pressed in. These nozzles will have the appearance of having a longer tip and shorter body. See pictures below. This change will not alter fit or performance in any way. Part Numbers Impacted
The table below lists part numbers impacted by this change.
Features and Benefits
Cat Remanufactured fuel nozzles 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 fuel nozzles. Cat Remanufactured fuel nozzles provide immediate, off-the-shelf availability at a fraction of the new price.
Features Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Caterpillar® parts distribution system
Customer access regardless of location
Backed by Cat warranty
Consistent support
Core Acceptance Core Acceptance Criteria for Caterpillar Remanufactured fuel nozzles is simple, visual, and requires no special tools. 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 (SELD00390, 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.
PELJ0505 CATERPILLAR® ?2005 Caterpillar