101501-2050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015012050 220009730a


 

Information injection-pump assembly

ZEXEL 101501-2050 1015012050
HINO 220009730A 220009730a
101501-2050 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101501-2050 1015012050
HINO 220009730A 220009730a


Zexel num
Bosch num
Firm num
Name
101501-2050 
101501-2051 
 
220009730A  HINO
INJECTION-PUMP ASSEMBLY
J07C * K

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

Test data 101501-2050
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 101501-2050
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 101501-2050
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)Lever free (4)Set the stopper screw. (After setting, apply red paint.)
----------
aa=38mm bb=17.8+-0.2mm cc=0r/min
----------
a=(40deg) b=33deg+-5deg c=7deg+-5deg d=0deg+-5deg

Timing setting

Test data 101501-2050
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

CAT REMAN ANNOUNCES THE RELEASE OF AN ELECTRONIC UNIT FUEL INJECTOR FOR CERTAIN 3600 AND C280 ENGINES
Announcement
Cat Reman announces the release of an electronic unit fuel injector for certain 3600 and C280 marine, petroleum, industrial and locomotive engines. Reman fuel injectors provide dealers and customers with additional replacement and repair options. Refer to the following table for part number details.
For serial number specific information, please see SISWEB.
Availability
The above fuel injector may be on initial seed support. For parts on initial seed support ANTARES may show "0" on-hand quantity for the Reman part number, however, orders for Reman will be filled with the new part equivalent. When Reman is the preferred option always order under the Reman part number regardless of what the system shows for on-hand. As long as the new equivalent part number has on-hand available the Reman order will be filled. For more details on the Reman seed policy please refer to the "Reman Parts Availability & Seeding Policy" information release memo, PELJ0816-01.
Features and Benefits
Cat Reman fuel 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 fuel injectors. Cat Reman parts 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 Cat? parts distribution system
Customer access regardless of location
Backed by Cat parts warranty
Consistent support
Core Acceptance
Core Acceptance Criteria for Cat Reman parts is simple, visual, and requires no special tools. Consult the Unit Injector Electronic Core Acceptance Criteria (SELD0226) for complete details.
Warranty
Please consult the appropriate Cat?parts warranty statement for your area.
Core Management
Please refer to the Cat Core Management Information System (CMIS 2) Parts Information application describing all Cat 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 https://catreman.cat.com. If you have any questions regarding core return processing, feel free to call Corinth 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 also 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.
Contact Information:
Global Dealer Solutions Network
Parts Technical Support Team
Toll Free - North America: 1-877-228-2420
International: +1-309-266-4421
Email: Tech_Support@Cat.com
CAT, CATERPILLAR,

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