Information injection-pump assembly
ZEXEL
101501-2010
1015012010
HINO
220008700A
220008700a
Rating:
Cross reference number
ZEXEL
101501-2010
1015012010
HINO
220008700A
220008700a
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
105780-8250
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 72 71.75 72.25
Cyl.1-2 deg. 72 71.75 72.25
Difference between angles 2
Cal 1-4 deg. 144 143.75 144.25
Cal 1-4 deg. 144 143.75 144.25
Difference between angles 3
Cal 1-5 deg. 216 215.75 216.25
Cal 1-5 deg. 216 215.75 216.25
Difference between angles 4
Cal 1-3 deg. 288 287.75 288.25
Cal 1-3 deg. 288 287.75 288.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.4
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
103.5
101.9
105.1
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(12.4)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
103.5
102.5
104.5
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.
105
101
109
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.35
Pump speed
r/min
1160
1160
1160
Average injection quantity
mm3/st.
105
101
109
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1-0.8
Pump speed
r/min
580
580
580
Average injection quantity
mm3/st.
89.5
85.5
93.5
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
E
Rack position
R1-0.95
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
82.5
78.5
86.5
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
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.
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.
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
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=J93
----------
----------
T1=J93
----------
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=36deg+-3deg
----------
aa=46mm
----------
a=8deg+-5deg b=36deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Use the hole at R = aa
(2)Rack position = bb (speed lever full, speed = cc).
(3)Free
(4)Set the stopper screw. (After setting, apply red paint.)
----------
aa=50mm bb=16.2+-0.2mm cc=0r/min
----------
a=(40deg) b=30deg+-5deg c=10deg+-5deg d=0deg+-5deg
----------
aa=50mm bb=16.2+-0.2mm cc=0r/min
----------
a=(40deg) b=30deg+-5deg c=10deg+-5deg d=0deg+-5deg
0000001501 LEVER
1. ASR lever adjustment
(1)At pump speed N1 adjust bolt (A) so that ASR lever clearance is approx. L at full load.
----------
N1=300r/min L=2mm
----------
----------
N1=300r/min L=2mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
REM06-45
Reman
December 2006 REMANUFACTURED UNIT INJECTOR ROCKER ARM ASSEMBLIES FOR CERTAIN C15 ENGINE APPLICATIONS Announcement The Caterpillar Remanufactured Products Group announces the expansion of the remanufactured product line to support C15 engine components for On-Highway applications with ACERT? Technology.Coverage
These Reman engine components provide dealers with additional repair options to support C15 engine applications.
The 10R4704 Reman Unit Injector Rocker Arm is for use in C15 On-Highway engines. These applications include truck engines hauling coal and timber (refer to the chart for specific serial number prefixes).
The 10R1136 Reman Unit Injector Rocker Arms is for use in all other C15 engine applications. This includes all C15 engines used in the machine, generator set, marine, industrial, and petroleum applications.
New Part Number Application Serial Number Prefix Reman Part Number
126-0888, 130-0075, 137-4060, 162-9174, 192-8215, 207-5248, 278-1365 On-Highway Truck Engine MBN, MXS, BXS, NXS 10R4704
All other applications All other serial number prefixes 10R1136 Features And Benefits
Cat? Remanufactured Engine Components 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 Engine Components. Cat Remanufactured Engine Components 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 (SELD0212) for Caterpillar Remanufactured Rocker Arm Assemblies 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 (SELD0039), go to the Reman Dealer website
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 Help Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0737 CATERPILLAR? ?2006 Caterpillar