101602-4962 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016024962 1156021274


 

Information injection-pump assembly

ZEXEL 101602-4962 1016024962
ISUZU 1156021274 1156021274
101602-4962 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101602-4962 1016024962
ISUZU 1156021274 1156021274


Zexel num
Bosch num
Firm num
Name
101602-4962 
101602-4963 
 
1156021274  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T *

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   131424-4920
Overflow valve opening pressure kPa   127 107 147
Overflow valve opening pressure kgf/cm2   1.3 1.1 1.5
Tester oil delivery pressure kPa   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.4 3.35 3.45
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   7.7
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   65 63.5 66.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.2+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 

Test data Ex:

Governor adjustment

Test data 101602-4962
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Rack difference between N = N1 and N = N2
----------
K=17 N1=1100r/min N2=700r/min
----------

Speed control lever angle

Test data 101602-4962
F:Full speed I:Idle D:Dead point
----------

----------
a=18deg+-1deg b=30deg+-5deg c=(20deg)+-3deg

Stop lever angle

Test data 101602-4962
N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=2.5deg+-5deg b=46deg+-5deg

0000001501 LEVER

Test data 101602-4962
1. Variable lever adjustment (1)Fix lever (B) in the idle position using bolts (C) and (D). (2)Temporarily fix the lever (A) in the center of the elongated hole. (3)Set the dead point position temporarily and measure the lever angle. (4)Fix the lever (A) at the idle lever angle position using the bolt (E). (5)Lock using bolt (G). (6)After completing idle adjustment, loosen the full side stopper bolt (D). (7)Move the lever (A) in the full speed direction. (8)Fix bolt (D) at full speed position. (9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------

----------

Timing setting

Test data 101602-4962
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(100deg)




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

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