101322-0240 ZEXEL 9 400 613 524 BOSCH INJECTION-PUMP ASSEMBLY 9400613524 1013220240 8941372900

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 524 9400613524

ZEXEL 101322-0240 1013220240

ISUZU 8941372900 8941372900

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106871-8991 as _

Cross reference number

BOSCH 9 400 613 524 9400613524

ZEXEL 101322-0240 1013220240

ISUZU 8941372900 8941372900

Zexel num

Bosch num

Firm num

Name

101322-0240

9 400 613 524

8941372900 ISUZU

INJECTION-PUMP ASSEMBLY
3AD1 * K

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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-2

Pre-stroke mm 1.75 1.7 1.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 2
Cyl.1-2 deg. 240 239.5 240.5

Injection quantity adjustment

Adjusting point A

Rack position 11.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 31.9 30.9 32.9

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.2+-0.5

Pump speed r/min 385 385 385

Average injection quantity mm3/st. 8 6.9 9.1

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

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)At rack cap installation: R1
----------
K=7 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Cancel spring dead point
----------

----------
a=6deg b=30deg+-5deg c=16deg+-5deg d=32deg+-3deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Z' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=24deg
----------
a=(120deg)

Information:

Tooling, Test, and Bulk Ground Fill Support Equipment
Diesel Exhaust Fluid (DEF)
Two container sizes of DEF are available through the Cat® dealers in North America. DEF must meet ISO 22241-1 specifications.
Table 1
Tool Part Number Description
350-8733 Diesel Exhaust Fluid 9.5 L (2.5 US gal) bottle
350-8734 Diesel Exhaust Fluid 1378 L (364 US gal) tote
443-0955 Removal Tool DEF filter removal tool Dispensing Equipment
Three different dispensing kits are offered to protect DEF quality. Optional flow meter and coupler are also available.
Table 2
Tool Part Number Description
422-1185 Pump Adapter (DEF DISPENSER) 12 V dispenser unit
423-7843 Pump Adapter (DEF DISPENSER) 110 V dispenser unit
423-7844 Pump Adapter (DEF DISPENSER) 230 V dispenser unit with"smart start"tote base
423-7795 Flow Meter In line DEF flow meter
423-7799 Coupler MicroMatic coupler Dispenser Unit Repair Parts
Table 3
Tool Part Number Description
436-6643 Repair Kit 12 V dispenser unit
436-6646 Diesel Exhaust Fluid Pump 12 V repair group
436-6642 Hose 20'/4'
436-6644 Swivel
436-6645 Repair Kit 1/2 hp pump
436-6647 Nozzle (DIESEL EXHAUST FLUID) Dispensing nozzle Storage and Transportation
Preventing DEF contamination does not stop at the pump. Protect your DEF supply with climate-specific enclosures and transportation tanks.
Table 4
Part Number Description
435-8671 Dispenser Warm-weather enclosure
435-8672 Dispenser Cold-weather enclosure
460-4077 Tank 121 L (32 US gal)
460-4078 Tank 269 L (71 US gal) Fast Fill Vehicle Interface
Illustration 1 g06516654
584-9979 Nozzle As
Table 5
584-9979 Nozzle As
Repair parts for 584-9979 Nozzle As
- 587-3371 Rear Cap
- 587-3372 Handle
- 587-3373 Hose (3/4")
- 587-3374 O-Ring Seal
- 587-3375 Handle (optional)
459-9296 Receiver As (Permanently mounted on vehicle)
For heated DEF hose repair connectors, kits, and instructions , refer to Service Magazine, M0103829, "Repair Kits for Quick Connect Diesel Exhaust Fluid (DEF) Line Fittings Are Now Available for Certain Cat® Machine Engines". Testing Equipment
Test your DEF supply and DEF injector with DEF-specific testing equipment. Complete kits or individual testing components are available for your needs.
Table 6
441-0451 Tool Gp (includes hard case, foam insert, and hardware)
- 441-0454 Container
- 443-7055 Test Kit
- 398-4985 Probe
- 398-4987 Probe
- 398-5080 Lead
- 398-5081 Lead
- 398-5083 Plug
450-1515 Tool Gp (DIESEL EXHAUST FLUID) (includes hard case, foam insert, and hardware)
- 441-0454 Container
- 398-4985 Probe
- 398-4987 Probe
- 398-5080 Lead
- 398-5081 Lead
- 398-5083 Plug
441-0454 Container
443-7055 Test Kit
431-7087 Tool Gp (REFRACTOMETER (DEF))
360-0774 Refractometer
372-5260 Test Lead Tool Group
576-6134 Test Strip