101603-7276 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037276


 

Information injection-pump assembly

ZEXEL 101603-7276 1016037276
101603-7276 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101603-7276 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7276 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4881
3. GOVERNOR 105931-6753
4. SUPPLY PUMP 105220-5930
5. AUTOM. ADVANCE MECHANIS 105644-0440
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5095
11. Nozzle and Holder 1-15300-266-4
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3862
14. NOZZLE 105017-1111
15. NOZZLE SET

Include in #1:

101603-7276 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7276 1016037276


Zexel num
Bosch num
Firm num
Name
101603-7276 
 
   
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   105780-8140
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   3.6 3.55 3.65
Rack position
After adjusting injection quantity.
  R=A
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   -
Rack position   13.2
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   95.7 94.1 97.3
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   275 275 275
Average injection quantity mm3/st.   8 6.7 9.3
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(13.2)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   95.7 94.7 96.7
Basic   *
Fixing the lever   *
Boost pressure kPa   28 28
Boost pressure mmHg   210 210
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.15
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   96.7 93.5 99.9
Fixing the lever   *
Boost pressure kPa   28 28
Boost pressure mmHg   210 210
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 55)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   77 73.8 80.2
Fixing the lever   *
Boost pressure kPa   28 28
Boost pressure mmHg   210 210
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-0.85
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   61.9 58.7 65.1
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   93 93 125
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   R2-0.85
Boost pressure kPa   3.3 3.3 6
Boost pressure mmHg   25 25 45
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   R2(R1-0. 55)
Boost pressure kPa   14.7 14.7 14.7
Boost pressure mmHg   110 110 110
Timer adjustment
Pump speed r/min   (1170)
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1325
Advance angle deg.   1.5 1 2
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7276
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=F36 BCL=0.85+-0.1mm
----------

Speed control lever angle

Test data 101603-7276
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=(37deg)+-3deg

Stop lever angle

Test data 101603-7276
N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101603-7276
(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=10deg
----------
a=(60deg)




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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