101401-2034 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012034

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-2034 1014012034

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Cross reference number

ZEXEL 101401-2034 1014012034

Zexel num

Bosch num

Firm num

Name

101401-2034

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.17 3.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 10.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 76.5 80.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.7)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 77.5 79.5

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 84.5 82.5 86.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 82.3 78.3 86.3

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 62.7 58.7 66.7

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_07

Adjusting point E

Rack position -

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 50 48 52

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_08

Adjusting point I

Rack position 14.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110 120

Fixing the lever *

Rack limit *

Injection quantity adjustment_09

Adjusting point K

Rack position R2(9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 39.3 35.3 43.3

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R2(9)

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1-0.5

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B31 BCL=(1.2)+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-5deg b=(43deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=13deg+-5deg b=40deg+-5deg

0000001501 ACTUATOR

(a) Screw (B) Nut (c) set bolt (d) control lever 1. Actuator adjustment procedure (1)Position the control lever (d) in the idling position. (2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator. (5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0. (7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=9.1~9.4mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Revised Service Letter replaces the October 20, 1993 Service Letter. Changes have been made to the Action Required.
Termination Date
January 31, 1994Problem
Certain 7N0449, 1W5829, 4W1819, 4W8483, 7W3710 and 1010060 Nozzle Assemblies need to be removed from Parts Stock because they may crack at the braze joint.
Action Required
Remove all 7N0449, 1W5829, 4W1819, 4W8483, 7W3710 and 1010060 Nozzle Assemblies from Parts Stock with a date code of D--3, E--3, F--3, or G--3. Refer to the Illustration below for the location of the date code. The date codes will appear as a letter followed by three numbers. The letter denotes the month, the first two numbers denote the day of the month, and the number 3 denotes the year. For example, D223 is the date code for April 22, 1993.
Location of Date CodeService Claim Allowances
Submit one claim for all 7N0449, 1W5829, 4W1819, 4W8483, 7W3710 and 1010060 Nozzle Assemblies removed from Parts Stock.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Parts Disposition
U.S. and Canadian Dealers
Return all 7N0449, 1W5829, 4W1819, 4W8483, 7W3710 and 1010060 Nozzle Assemblies that are removed from Parts Stock and a copy of the claim to:
CaterpillarInc.
Attn:HowardJenkel/PI7324
Warehouse#4Docks7thru10
8201N.University
Peoria,IL 61615
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.