Information injection-pump assembly
ZEXEL
101692-3560
1016923560
Rating:
Cross reference number
ZEXEL
101692-3560
1016923560
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive 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
Rack position
(10.1)
Vist
V
1.99
1.99
1.99
Pump speed
r/min
1025
1025
1025
Average injection quantity
mm3/st.
68.2
67.2
69.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Remarks
Point A
Point A
Injection quantity adjustment_02
Rack position
(8.8)
Vist
V
2.2
2.1
2.3
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
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aa=16mm bb=1mm
----------
a=19deg+-5deg b=29deg+-5deg
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aa=16mm bb=1mm
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a=19deg+-5deg b=29deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
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a=58deg+-3deg b=2deg+-30min
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a=58deg+-3deg b=2deg+-30min
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:
Emissions Warranty
Caterpillar Inc. warrants to the initial owner and subsequent owner of a diesel truck engines (powering on-highway trucks), that such engine is ...1. Designed, built and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the United States Environmental Protection Agency (EPA).2. Free from defects in materials and workmanship in specific emission related parts for a period of 60 months, 100,000 miles (161 000 km) or 3,000 hours of operation, whichever occurs first, after date of delivery to the initial owner.If an emission related part fails during the warranty period, it will be repaired or replaced. Any such part repaired or replaced under warranty is warranted for the remainder of the warranty period.During the term of this warranty, Caterpillar Inc. will provide through a Caterpillar dealer or other establishment authorized by it, repair or replacement of any warranted part at no change to the truck engine owner.In an emergency, repairs may be performed at any service establishment, or by the owner, using any replacement part.Caterpillar Inc. will reimburse the owner for their expenses, including diagnostic charges for such emergency repair. These expenses shall not exceed Caterpillar Inc. suggested retail price for all warranted parts replaced, and labor charges based on Caterpillar Inc. recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate.As a condition of reimbursement, replaced parts and receipted invoices must be presented at a place of business of a Caterpillar dealer or other establishment authorized by Caterpillar Inc.Limitations & Responsibilities
The warranty is subject to the following:Caterpillar Inc. Responsibilities
During the emission warranty period, if a defect in material or workmanship of an emission related part or component is found, Caterpillar Inc. will provide:* New, Remanufactured or repaired parts and/or components, approved pursuant to EPA Regulations, required to correct the defect. Items replaced under this warranty become the property of Caterpillar Inc.* Reasonable and customary labor, during normal working hours, required to make the warranty repair. This includes labor to remove and install the engine, if necessary.Owner Responsibilities
During the emission warranty period, the owner is responsible for:* Premium or overtime labor costs, unless essential to prevent loss to perishable goods.* Costs to investigate complaints which are not caused by a defect in Caterpillar Inc. material or workmanship.* Providing timely notice of a warrantable failure and promptly making the product available for repair.Limitations
Caterpillar Inc. is not responsible for resultant damages to an emission related part or component resulting from:* Any application or installation Caterpillar Inc. deems improper.* Attachments, accessory items or parts not sold nor approved by Caterpillar Inc.* Improper truck engine maintenance, repair or abuse.* Owner's unreasonable delay in making the product available after being notified of a potential product problem.This warranty is in addition to Caterpillar Inc. standard warranty, applicable to the truck engine product involved.Remedies under this warranty are limited to the provision of material and services as specified herein. Caterpillar Inc. is not responsible for incidental or consequential damages.
Caterpillar Inc. warrants to the initial owner and subsequent owner of a diesel truck engines (powering on-highway trucks), that such engine is ...1. Designed, built and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the United States Environmental Protection Agency (EPA).2. Free from defects in materials and workmanship in specific emission related parts for a period of 60 months, 100,000 miles (161 000 km) or 3,000 hours of operation, whichever occurs first, after date of delivery to the initial owner.If an emission related part fails during the warranty period, it will be repaired or replaced. Any such part repaired or replaced under warranty is warranted for the remainder of the warranty period.During the term of this warranty, Caterpillar Inc. will provide through a Caterpillar dealer or other establishment authorized by it, repair or replacement of any warranted part at no change to the truck engine owner.In an emergency, repairs may be performed at any service establishment, or by the owner, using any replacement part.Caterpillar Inc. will reimburse the owner for their expenses, including diagnostic charges for such emergency repair. These expenses shall not exceed Caterpillar Inc. suggested retail price for all warranted parts replaced, and labor charges based on Caterpillar Inc. recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate.As a condition of reimbursement, replaced parts and receipted invoices must be presented at a place of business of a Caterpillar dealer or other establishment authorized by Caterpillar Inc.Limitations & Responsibilities
The warranty is subject to the following:Caterpillar Inc. Responsibilities
During the emission warranty period, if a defect in material or workmanship of an emission related part or component is found, Caterpillar Inc. will provide:* New, Remanufactured or repaired parts and/or components, approved pursuant to EPA Regulations, required to correct the defect. Items replaced under this warranty become the property of Caterpillar Inc.* Reasonable and customary labor, during normal working hours, required to make the warranty repair. This includes labor to remove and install the engine, if necessary.Owner Responsibilities
During the emission warranty period, the owner is responsible for:* Premium or overtime labor costs, unless essential to prevent loss to perishable goods.* Costs to investigate complaints which are not caused by a defect in Caterpillar Inc. material or workmanship.* Providing timely notice of a warrantable failure and promptly making the product available for repair.Limitations
Caterpillar Inc. is not responsible for resultant damages to an emission related part or component resulting from:* Any application or installation Caterpillar Inc. deems improper.* Attachments, accessory items or parts not sold nor approved by Caterpillar Inc.* Improper truck engine maintenance, repair or abuse.* Owner's unreasonable delay in making the product available after being notified of a potential product problem.This warranty is in addition to Caterpillar Inc. standard warranty, applicable to the truck engine product involved.Remedies under this warranty are limited to the provision of material and services as specified herein. Caterpillar Inc. is not responsible for incidental or consequential damages.