101401-4910 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014910

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-4910 1014014910

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Service parts 101401-4910 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8260

3. GOVERNOR 105932-0700

4. SUPPLY PUMP 105210-6100

5. AUTOM. ADVANCE MECHANIS 105676-5100

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5882

11. Nozzle and Holder 8-97074-876-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE 105017-1710

15. NOZZLE SET

Include in #1:

101401-4910 as INJECTION-PUMP ASSEMBLY

106671-8180 as _

Cross reference number

ZEXEL 101401-4910 1014014910

Zexel num

Bosch num

Firm num

Name

101401-4910

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-3-4-2

Pre-stroke mm 4.1 4.05 4.15

Rack position
Point A R=A

Beginning of injection position
Governor 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 12.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 67.5 65.9 69.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 15.5 14.2 16.8

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(12.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 67.5 66.5 68.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 83.5 79.5 87.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 47.8 43.8 51.8

Fixing the lever *

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.15

Pump speed r/min 1280 1280 1280

Average injection quantity mm3/st. 78.5 74.5 82.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

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.
----------
T1=J76
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=41deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)At pump speed bb and rack position cc, set the stopper bolt. (3)Actual measurement
----------
aa=25mm bb=1600r/min cc-5.5-0.5mm
----------
a=15deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

0000001601 RACK SENSOR

Rack sensor adjustment (1)These types of rack sensors do not need adjustment. Confirm the output as described below. (2)Mount the rack sensor main body to the pump main body. (3)Measure the Vist at pump speed N1 and rack position Ra.
----------
N1=1600r/min Ra=R1(12.5)+0.25mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)Pump bracket check hole position. (5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (6)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)

Information:

Gauges provide indications of engine performance. Be sure they are in good working order. You can determine what is the "normal" operating range by observing the gauges over a period of time.Noticeable changes in gauge readings indicate potential gauge or engine problems. This also applies to gauge readings that have changed significantly, but are still within specifications. The cause of any sudden or significant change in gauge readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed.
Oil Pressure - Indicated engine oil pressure. The oil pressure should be greatest after starting a cold engine. Oil pressure should read between 275 and 606 kPa (40 and 88 psi) when: the engine is running at rated engine speed with SAE 10W30 oil, with an oil temperature no more than 110°C (230°F). A lower pressure is normal at low idling speed.If the oil pressure readings fluctuate after the load has stabilized:1. Remove the load.2. Reduce the engine speed to low idle.3. Check the oil level, and add oil if necessary.The minimum recommended oil pressure at 600 rpm is 103 kPa (15 psi). If low oil pressure or no oil pressure is indicated, stop the engine and determine the cause of the problem. Refer to the Troubleshooting section of the Service Manual, or consult with your Caterpillar dealer.
Engine damage can result if the engine is operated with no oil pressure gauge reading. If no pressure is indicated, stop the engine.
Jacket Water Temperature - Indicates engine coolant temperature. It should normally indicate between 87 to 98°C (189 to 209°F). Higher temperatures may occur under certain conditions. Maximum allowable temperature is 104°C (220°F) with the cooling system pressurized.If the engine is operating with a jacket water temperature above this range:1. Reduce the load and rpm.2. Look for coolant leaks.3. Determine if the engine must be shut down immediately, or if the engine can be cooled by reducing the load.
Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).Check the charging system for malfunction if, during operation, the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge.
Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding can seriously damage your engine.
Do not exceed "bare engine high idle" rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. The electrically operated fuel level gauge registers only when the START/STOP (ignition key) switch is ON.
Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 160 kPa (23 psi) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter.
Service Hour Meter - Indicates the total number of service meter