Information injection-pump assembly
ZEXEL
101491-0292
1014910292
ISUZU
8941788182
8941788182

Rating:
Cross reference number
ZEXEL
101491-0292
1014910292
ISUZU
8941788182
8941788182
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
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
10.2
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
49.2
47.6
50.8
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
-
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.
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
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
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.6
Timer adjustment_03
Pump speed
r/min
1900
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

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

F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=5.5deg+-5deg b=37deg+-3deg
----------
----------
a=5.5deg+-5deg b=37deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=40deg+-5deg
----------
----------
a=45deg+-5deg b=40deg+-5deg
0000001501 ACS

(A) Housing
(B) Snap ring
(C) adjusting screw
(D) Set screw
(E): Push rod
(F) Spacer
1. Adjustment of the aneroid compensator
(1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1.
(2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2.
(3)(C) Turn the screw to adjust the beginning of aneroid compensator operation.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Adjust using screw C to obtain the performance shown in the graph above.
(3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=1100r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(10.2)mm Rb=(R1-0.4)mm Pa=4+-2.7kPa(30+-20mmHg) Pb=22kPa(165mmHg) Q1=49.2+-1cm3/1000st Q2=41.1+-1cm3/1000st
----------
N1=1100r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(10.2)mm Rb=(R1-0.4)mm Pa=4+-2.7kPa(30+-20mmHg) Pb=22kPa(165mmHg) Q1=49.2+-1cm3/1000st Q2=41.1+-1cm3/1000st
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=15deg
----------
a=(90deg)
----------
aa=15deg
----------
a=(90deg)
Information:
SEPTEMBER 2009
INFORMATION RELEASE MEMO
Reman
PELJ1080 ?2009 Caterpillar
CAT REMAN ANNOUNCES THE INTRODUCTION OF AN UPGRADE TO NEW INJECTOR KIT FOR CERTAIN HIGH DISPLACEMENT 3500 ENGINES IN MINING APPLICATIONS
Announcement
Some mining customers have expressed a preference to use new fuel injectors during an engine rebuild as part of a bill of materials designed to produce a "zero" hour rebuilt engine standard. To provide an economical option to those customers, Cat Reman announces the introduction of an Upgrade to New (UTN) fuel injector kit option for certain 3500 engines in mining applications. This option will meet the customer need while enabling Cat Reman to capture the cores of those customers using new injectors.
These fuel injector kits will provide dealers and customers with an additional fuel injector replacement and repair option and come complete with four new fuel injectors and corresponding hold down bolts. Refer to the following table for part number details.
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Availability and Ordering
To support availability of these UTN kits for planned rebuilds, we ask dealers to place Future Dated Orders (FDOs) whenever possible.
Core Acceptance
Core Acceptance Criteria for CatP?PFuel Injectors is simple, visual, and requires no special tools. Consult the Unit Injectors ? Electronic Core Acceptance Criteria SELD0226 for complete details. The purchase of an UTN Kit establishes core entitlements at the consist part level quantity. For example, purchase of a kit of four UTN Injectors establishes four individual core injector entitlements.
Warranty
Please consult the appropriate CatP Pparts 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.
For assistance with technical questions, call the Peoria Reman Technical Help Line toll free at (888) 88-REMAN (outside the US call non-toll free +1-309-494-4342), or use our E-mail address--Reman_Help.