101501-2030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015012030


 

Information injection-pump assembly

ZEXEL 101501-2030 1015012030
101501-2030 INJECTION-PUMP ASSEMBLY
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Service parts 101501-2030 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101050-0080
3. GOVERNOR 105932-1690
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:

101501-2030 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101501-2030 1015012030


Zexel num
Bosch num
Firm num
Name
101501-2030 
 
   
INJECTION-PUMP ASSEMBLY

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 12 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

Test data 101501-2030
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

Test data 101501-2030
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

Test data 101501-2030
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg

Timing setting

Test data 101501-2030
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:


Table Continued:
Engine Model Reman Kit Part Number Kit Consist New Equivalent Part Number Part Description Qty per Kit Date Available
C15 ACERT 10R9236 10R1273 2490709 INJECTOR GP-FUEL 6 1-Jul-09
1R0749 1R0749 FILTER AS.-FUEL 1
8S9191 8S9191 BOLT 6
Features and Benefits
Cat? 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 many benefits. Customers save time by installing all injectors in one service call instead of having multiple service calls to install injectors one or two at a time. Customers save money by eliminating redundant labor costs and down time due to multiple service calls to replace injectors only when they fail. Cat Reman Injector Kits also offer the convenience of delivering all components necessary to do injector replacements in one box under one part number and additionally include a replacement secondary fuel filter.
In addition to saving time and money, customers who install a Cat Reman Injector Kit will maximize their engine performance, optimize fuel economy and restore the operation of their 3126B, C-12, and C15 ACERTTM engines for years to come.
Features Benefits
All critical engineering changes and updates included Improved reliability and performance
Worldwide availability through Cat parts distribution system Customer access regardless of location
Backed by Cat parts warranty Consistent support
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured Fuel Injectors is simple, visual, and requires no special tools. Consult the Unit Injectors ? Electronic Core Acceptance Criteria SELD0226 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.
Warranty
Please consult the appropriate Cat? parts 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.
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