Information injection-pump assembly
ZEXEL
101902-0051
1019020051
ISUZU
1156011901
1156011901
Rating:
Cross reference number
ZEXEL
101902-0051
1019020051
ISUZU
1156011901
1156011901
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 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
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
R: right hand row, L: left hand row 1L-8R-7L -3L-6R-5 L-4R-2R
R: right hand row, L: left hand row 1L-8R-7L -3L-6R-5 L-4R-2R
Pre-stroke
mm
4.4
4.35
4.45
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5
Cal 1-8 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-4 deg. 270 269.5 270.5
Cal 1-4 deg. 270 269.5 270.5
Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5
Cyl.1-2 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.2
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
134.8
133.8
135.8
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
81.3
81.3
Boost pressure
mmHg
610
610
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.2+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
16.7
15.3
18.1
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
8.1
Boost pressure
kPa
10.7
8
13.4
Boost pressure
mmHg
80
60
100
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
10.2
Boost pressure
kPa
64
53.3
74.7
Boost pressure
mmHg
480
400
560
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Excessive fuel setting for starting using boost compensator lever: SXL
(3)Boost compensator stroke
----------
K=9 SXL=10.2+0.2mm
----------
----------
K=9 SXL=10.2+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
(1)Stopper bolt setting
----------
----------
a=25deg+-5deg b=32deg+-5deg c=0deg+6deg
----------
----------
a=25deg+-5deg b=32deg+-5deg c=0deg+6deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
0000001101
N:Normal
B:When boosted
----------
----------
a=(10deg) b=(15deg)
----------
----------
a=(10deg) b=(15deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear shaft's key groove at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(120deg)
----------
aa=16deg
----------
a=(120deg)
Information:
REM05-07
Reman
January 2005 APPEARANCE CHANGE TO REMAN 3400 HEUI? INJECTORS Announcement The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat Reman 3400 HEUI injectors effective 01/31/05. In order to improve appearance and salvage of injector stator covers, Cat Reman will begin using stator cover marking plates on selected 3400 HEUI injectors. Currently, Cat Reman must remove the old part number and codes from the stator cover by grinding. This process can only be done once and often opens porosity in the stator causing scrap or unacceptable appearance. Effective 01/31/05 Cat Reman will begin using a disposable marking plate. See the pictures below. The cover and stator are not serviced separately; the picture is for clarity only. This change will not alter fit or performance in any way. Part Numbers ImpactedThe table below lists part numbers impacted by this change.
Reman Part Numbers Description
10R1265 FUEL INJECTOR GP
10R1266 FUEL INJECTOR GP
10R1267 FUEL INJECTOR GP 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 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 warranty
Consistent support
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. 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
PELJ0493 CATERPILLAR? ?2005 Caterpillar