Information injection-pump assembly
ZEXEL
101603-7081
1016037081
ISUZU
1156025150
1156025150
Rating:
Cross reference number
ZEXEL
101603-7081
1016037081
ISUZU
1156025150
1156025150
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
105780-8140
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
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.7
3.65
3.75
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
104.6
103
106.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
290
290
290
Average injection quantity
mm3/st.
9.9
7.9
11.9
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.5)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
104.6
103.6
105.6
Basic
*
Fixing the lever
*
Remarks
After setting aneroid compensatory.
After setting aneroid compensatory.
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.4
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
99.4
96.2
102.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
98
98
108
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
2
1.5
2.5
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=E01
----------
----------
T1=E01
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18deg+-5deg b=31deg+-3deg
----------
----------
a=18deg+-5deg b=31deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Upper lever angle
(2)Stopper bolt setting
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 ACS
(A) Housing
(B) Snap ring
(C) adjusting screw
(D) Set screw
(E): Push rod
(F) Spacer
1. Adjustment of the aneroid compensator
(1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1.
(2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2.
(3)(C) Turn the screw to adjust the beginning of aneroid compensator operation.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Adjust using screw C to obtain the performance shown in the graph above.
(3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(12.5)mm Rb=(R1-0.45)mm Pa=92.6+-2.7kPa(695+-20mmHg) Pb=65.3+-0.7kPa(490+-5mmHg) Q1=104.6+-1cm3/1000st Q2=92.6+-1.6cm3/1000st
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(12.5)mm Rb=(R1-0.45)mm Pa=92.6+-2.7kPa(695+-20mmHg) Pb=65.3+-0.7kPa(490+-5mmHg) Q1=104.6+-1cm3/1000st Q2=92.6+-1.6cm3/1000st
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(40deg)
----------
aa=11deg
----------
a=(40deg)
Information:
Information Release Memo REM03-28
Reman
September 2003 REMANUFACTURED FUEL INJECTORS FOR VARIOUS INDUSTRIAL, MACHINE, AND ON-HIGHWAY TRUCK APPLICATIONS Announcement The Caterpillar Remanufactured Products Group announces the expansion of the remanufactured injector product line to include additional coverage for various 3126B, 3126E C10, C12, 3176, and 3196 Industrial, Machine, Marine and On-Highway Truck applications. Coverage The addition of these injectors provides dealers with an additional repair option to support various 3126B, 3126E, C10, C12, 3176, and 3196 Industrial, Machine and On-Highway Truck applications. Coverage is extensive so please consult your NPR or Reman Cross Reference for exact model coverage. Features And Benefits Cat? Remanufactured 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 injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price. Features
All critical engineering changes and updates included
Worldwide availability through Caterpillar? parts distribution system
Backed by Cat warrantyBenefits
Improved reliability and performance
Customer access regardless of location
Consistent supportCore Acceptance Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Full core credit is issued when the core is complete, fully assembled, and has an acceptable part number. 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 https://reman.cat.com 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 Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0234 CATERPILLAR? ?2003 Caterpillar