101401-1624 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014011624

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-1624 1014011624

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Service parts 101401-1624 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9850

3. GOVERNOR 105921-6711

4. SUPPLY PUMP 105220-6050

5. AUTOM. ADVANCE MECHANIS 105676-0811

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5550

11. Nozzle and Holder ME016989

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3501

14. NOZZLE 105017-0590

15. NOZZLE SET

Include in #1:

101401-1624 as INJECTION-PUMP ASSEMBLY

108622-3433 as _

Cross reference number

ZEXEL 101401-1624 1014011624

Zexel num

Bosch num

Firm num

Name

101401-1624

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 131424-8820

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 11.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.9 72.3 75.5

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 Z

Rack position 9.5+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 19.5 18.2 20.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.9)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.9 72.9 74.9

Basic *

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.8

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 92.5 88.5 96.5

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-1)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 46.3 42.3 50.3

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.65

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 18.7 14.7 22.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-0.65

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-0. 65)

Boost pressure kPa 11.3 11.3 11.3

Boost pressure mmHg 85 85 85

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 4.5 4 5

Remarks
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)Boost compensator stroke: BCL
----------
T1=J00 BCL=0.65+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=40deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)At speed = bb and rack position = cc, confirm that the stopper bolt is set at the non-injection position. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee (non-injection rack position) (4)- (5)Rack position corresponding to ff (6)Free (at delivery)
----------
aa=40mm bb=1600r/min cc=5-0.5mm dd=325r/min ee=(8)--mm ff=16mm
----------
a=29deg+-5deg b=19deg+-5deg c=33deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1025r/min Ra=8.5+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)

Information:

AUGUST 2011
INFORMATION RELEASE MEMO
Reman
PELJ1306 ?2011 Caterpillar REMAN DIESEL PARTICULATE FILTERS FOR MACHINE APPLICATIONS
To provide our customers with cost effective service options to support their Tier 4 emissions engines, Cat Reman has released a Reman version of the diesel particulate filters (DPF) used on many Tier 4 Cat? machines. The DPF traps both soot and ash. Soot is removed through a regeneration process outlined in the machines operation and maintenance manual. Ash that accumulates from engine oil is removed through a cleaning procedure that requires removal of the DPF from the machine. The cleaning procedure requires the DPF to be removed from the machine. Special Instruction REHS5045 outlines the three approved processes for performing the required Diesel Particulate Filter (DPF) maintenance on Tier 4 products equipped with a DPF.
Replacement of the existing DPF with a new Cat DPF
Replacement of the existing DPF with a remanufactured Cat DPF
Removal of the existing DPF and having the DPF cleaned by a Cat approved cleaning device.
The Reman DPFs listed below are available to support these maintenance requirements:
Core Acceptance
After gaining some experience with the previously released DPFs used for on-highway engines and to support the launch of these additional machine DPFs, we have changed some of the inspection criteria and issued a revision to SELD0292. SELD0292-02 Caterpillar Diesel Particulate Filter (DPF) is the current Core Acceptance Criteria (CAC). It is critical to avoid non-operational damage that can decrease the value of the cores. Encourage service technicians to handle and package the cores with care so they will be more likely to be eligible for the full core refunds. Please always refer to the most current version at catreman.cat.com/core to view the latest requirements. The acceptability inspection for these is a simple visual inspection based on the following guidelines:
Warranty
All Reman products carry the same warranty as new parts. Please consult the appropriate warranty statement for your area.
Core Management
Please refer to the Cat Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as Policy and Core Management SELD0122 -10, "Core Management Systems and Operations Procedures SELD0040-14, "Reman Core Return Packaging Instructions And Guidelines SELD0300-00 and "Shipping Instructions" SELD0039-14.
If you have any questions regarding Reman Core Management or Core Management Systems (CMIS2),