101501-2003 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015012003

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101501-2003 1015012003

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Service parts 101501-2003 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101050-0070

3. GOVERNOR 105932-0674

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105672-5270

6. COUPLING PLATE 105662-1520

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7705

11. Nozzle and Holder 23600-2663C

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-3601

14. NOZZLE

15. NOZZLE SET 105019-0314

Include in #1:

101501-2003 as INJECTION-PUMP ASSEMBLY

Include in #2:

104761-4070 as _

Cross reference number

ZEXEL 101501-2003 1015012003

Zexel num

Bosch num

Firm num

Name

101501-2003

INJECTION-PUMP ASSEMBLY
14BL PE 5MD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131425-0320

Overflow valve opening pressure kPa 108 88 128

Overflow valve opening pressure kgf/cm2 1.1 0.9 1.3

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-2-4-5- 3

Pre-stroke mm 4 3.97 4.03

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 72 71.75 72.25

Difference between angles 2
Cal 1-4 deg. 144 143.75 144.25

Difference between angles 3
Cal 1-5 deg. 216 215.75 216.25

Difference between angles 4
Cal 1-3 deg. 288 287.75 288.25

Injection quantity adjustment

Adjusting point -

Rack position 12.2

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 100 98.4 101.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 415 415 415

Each cylinder's injection qty mm3/st. 12 11 13

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 100 99 101

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 103 99 107

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.45

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 105.5 101.5 109.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.75

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 84 80 88

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1-0.9

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 77 71 83

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 170 180

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 1/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Load 1/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.7 1.3

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1190++

Advance angle deg. 1 0.7 1.3

Load 2/5

Timer adjustment_05

Pump speed r/min (1300-50 )

Advance angle deg. 1 0.7 1.3

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_06

Pump speed r/min 1450-50

Advance angle deg. 5.5 5.2 5.8

Load 5/5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=K64
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=8deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)

Information:

REM06-08
Reman
May 2006 REMANUFACTURED INJECTORS FOR C7 AND C9 ENGINES WITH ACERT? TECHNOLOGY Announcement The Caterpillar Remanufactured Products Group announces expansion of the remanufactured injector product line to include coverage for Cat? C7 and C9 engines with ACERT? Technology for various on-highway, industrial, and machine applications. Coverage The addition of these Reman injectors provides dealers with an additional repair option to support various C7 and C9 engines with ACERT Technology. Please consult your NPR or Reman Cross Reference for exact model coverage. 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 by providing 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
Off the shelf availability
Reduced downtime
Backed by Cat warranty
Consistent support
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple. Full core credit is issued when the core is fully assembled, there is no excessive rust or non-operational damage and it is 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 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.
PELJ0637 CATERPILLAR? ?2006 Caterpillar