Information injection-pump assembly
ZEXEL
101501-2021
1015012021
HINO
220008710B
220008710b

Rating:
Service parts 101501-2021 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2663
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
14.
NOZZLE
Include in #1:
101501-2021
as INJECTION-PUMP ASSEMBLY
Include in #2:
104761-4013
as _
Cross reference number
ZEXEL
101501-2021
1015012021
HINO
220008710B
220008710b
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
12.2
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
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=K70
----------
----------
T1=K70
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=8deg+-5deg b=(47deg)+-3deg
----------
aa=41mm
----------
a=8deg+-5deg b=(47deg)+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. Confirm non-injection.
(3)After setting the stopper screw, confirm non-injection at N = dd and R = actual rack position. After setting apply red paint.
----------
aa=38mm bb=1750r/min cc=6.8-0.5mm dd=300r/min
----------
a=0deg+-5deg b=(28deg)+-5deg
----------
aa=38mm bb=1750r/min cc=6.8-0.5mm dd=300r/min
----------
a=0deg+-5deg b=(28deg)+-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)
----------
----------
a=(20deg)
Information:
REM08-21
Reman
August 2008 INTRODUCING REMAN INJECTOR KITS FOR 3406E, C-15 AND C-16 ON-HIGHWAY TRUCK ENGINES Announcement The Caterpillar Remanufactured Products Group announces two new Cat Reman injector kit options for 3406E, C-15 and C-16 on-highway truck engine applications. Cat Reman injector kits come complete with a full set of six Cat Reman fuel injectors and o-rings. CoverageCat Reman injector kits provide dealers with the option to purchase all six injectors together in one kit with one part number. Dealers who stock Cat Reman kits have the opportunity to improve their parts and service sales by having the right amount of inventory on the shelf and ready for both planned and unplanned injector repairs and Cat engine overhauls.Order and stock Cat Reman injector kits today and have peace of mind that your dealership has the right products in inventory to offer customers a wide variety of service repair options. The table below lists coverage based upon the new Cat injector part number.
* Each kit contains six individual injectors and o-rings. Features and BenefitsCat? Remanufactured Components offer your customers excellent value. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of Cat Reman injector kits. Cat Remanufactured Components provide immediate, off-the-shelf availability at a fraction of the new price. Cat Reman injector kits offer Cat engine users many benefits. Customers save time by installing all injectors in just one trip to the shop instead of making multiple trips to install injectors one or two at a time. Customers save money by eliminating redundant labor costs and time off the road due to multiple trips to the shop to replace injectors only when they fail.In addition to saving time and money, customers who install the Cat Reman injector kit will maximize their engine performance, optimize fuel economy and restore the operation of their Cat 3406E, C-15 and C-16 engines for years to come.
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 parts warranty
Consistent support
Core AcceptanceCore Acceptance Criteria for Caterpillar Remanufactured Components is simple, visual and requires no special tools. Consult your Unit Injector Electronic Core Acceptance Criteria SELD0226-01 for complete details. The purchase of a Reman Kit establishes core entitlements at the consist part level quantity. For example, purchase of a kit of six Reman Injectors establishes six individual core injector entitlements. WarrantyPlease consult the appropriate Cat parts warranty statement for your area. Return Status and Kit AvailabilityCat Reman injector kits are available when and where you need them most - the Cat parts distribution system. These Cat Reman injector kit product offerings will be stocked throughout the Cat distribution system and ready to fill dealer stock and emergency orders. Once on your shelf, dealers will now have the opportunity to promote the benefits of replacing a customer's old set of injectors with one Cat Reman injector kit. To ensure that