Information injection-pump assembly
ZEXEL
101401-4970
1014014970
ISUZU
8971154000
8971154000
Rating:
Cross reference number
ZEXEL
101401-4970
1014014970
ISUZU
8971154000
8971154000
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-3920
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
3.8
3.75
3.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.1
Pump speed
r/min
1160
1160
1160
Average injection quantity
mm3/st.
97
95.4
98.6
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
Z
Rack position
9.7+-0.5
Pump speed
r/min
285
285
285
Average injection quantity
mm3/st.
14.5
13.2
15.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.1)
Pump speed
r/min
1160
1160
1160
Average injection quantity
mm3/st.
97
96
98
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.35
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
96.5
92.5
100.5
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.45
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
86
82
90
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
95
95
127
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R2-0.45
Boost pressure
kPa
27.3
26
28.6
Boost pressure
mmHg
205
195
215
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R2(R1-0.
6)
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
Timer adjustment
Pump speed
r/min
1185--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1135
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
4.8
4.3
5.3
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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=K06 BCL=0.45+-0.1mm
----------
----------
T1=K06 BCL=0.45+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=42deg+-5deg b=(41deg)+-3deg
----------
----------
a=42deg+-5deg b=(41deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-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=1100r/min Ra=9.4+-0.1mm
----------
----------
N1=1100r/min Ra=9.4+-0.1mm
----------
0000001601 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=475r/min Ra=9.75+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=475r/min Ra=9.75+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
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)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1.
(5)B.T.D.C.: aa
----------
aa=6deg
----------
a=(60deg) b=(85deg)
----------
aa=6deg
----------
a=(60deg) b=(85deg)
Information:
Caterpillar Reference Material
The following literature can be obtained through any Caterpillar dealer.Oil
SEBD0640, Oil and Your EnginePEDP7122, Question & Answer BookletPEDP1129, Listen To Your OilPEHP6001, How to Take a Good Oil SampleSEBU6251, Lubricant RecommendationsPEHP1027, Product Data Sheet for Cat Diesel Engine Oil (CD)PEHP0002, Product Data Sheet for Cat Molybdenum Grease (MPGM)PEHP0003, Product Data Sheet for Cat Lithium Grease (MPGL)PEHP0017, Product Data Sheet for Cat Special Purpose Grease (SPG)PEWP9733, Cat Fluids SelectorPEDP7105, Scheduled Oil SamplingFuel
SEBD0717, Diesel Fuels and Your EngineCoolant
SEBD0518, Know Your Cooling SystemSEBD0970, Coolant and Your EngineMiscellaneous
SEBF8029, Index to Guidelines for Reusable Parts and Salvage OperationsSEBF8062, Guideline for Reusable Parts - Cleaning and Inspection of Air FiltersSEHS9031, Storage Procedure for Caterpillar ProductsSENR5226, Service Manual (EMCP)SEBU6150, SR4 Generators and Control Panels Operation and Maintenance ManualSEBU6918, SR4B Generators and Control Panels Operation and Maintenance ManualSENR7337, Service Manual, 3408 and 3408B Industrial and Marine EnginesSENR7405, Service Manual, 3412 Industrial and Marine EnginesSENR2559, Service Manual, 3408 and 3412 Generator Set EnginesSEHS7654, Alignment-General InstructionsSEHS9124, Cleaning and Drying of Caterpillar Electric Set GeneratorsLEBH9324, Agricultural and Material Handling Application and Installation GuideSEHS7292, Use of 5P4150 Nozzle Testing GroupSEHS8622, Using the FT1984 Air-To-Air Aftercooler Leak Test GroupSEHS7795, Use of Pump & Governor Tool GroupSEHS8024, Governor Adjusting Tool GroupSEHS8094, Use of Nozzle Puller GroupAdditional Reference Material
ASTM D2896- TBN MeasurementsASTM D21768- Worked PenetrationASTM D2982B- Ethylene Glycol ContentASTM D3828A- Fuel DilutionASTM D445- ViscosityASTM D893- InsolublesASTM 498589- GM-6038M SpecificationASTM Specs can normally be obtained from your local technological society, library or college.SAE J313- Diesel FuelsSAE J754- NomenclatureSAE J183- ClassificationSociety of Automotive Engineers (SAE) Specs can be found in your SAE handbook or can be obtained from your local library, college, or technological society.* SAE handbooks can be obtained directly from:SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
Engine Manufacturers Association (EMA) information for lube oil selection can be obtained from your local library, college or technological society, or contact:* Engine Manufacturers AssociationLubricating Oils Data Book
401 N. Michigan Ave. Ste. 2400
Chicago, IL 60611
(312) 644-6610 ext. 3626
The following literature can be obtained through any Caterpillar dealer.Oil
SEBD0640, Oil and Your EnginePEDP7122, Question & Answer BookletPEDP1129, Listen To Your OilPEHP6001, How to Take a Good Oil SampleSEBU6251, Lubricant RecommendationsPEHP1027, Product Data Sheet for Cat Diesel Engine Oil (CD)PEHP0002, Product Data Sheet for Cat Molybdenum Grease (MPGM)PEHP0003, Product Data Sheet for Cat Lithium Grease (MPGL)PEHP0017, Product Data Sheet for Cat Special Purpose Grease (SPG)PEWP9733, Cat Fluids SelectorPEDP7105, Scheduled Oil SamplingFuel
SEBD0717, Diesel Fuels and Your EngineCoolant
SEBD0518, Know Your Cooling SystemSEBD0970, Coolant and Your EngineMiscellaneous
SEBF8029, Index to Guidelines for Reusable Parts and Salvage OperationsSEBF8062, Guideline for Reusable Parts - Cleaning and Inspection of Air FiltersSEHS9031, Storage Procedure for Caterpillar ProductsSENR5226, Service Manual (EMCP)SEBU6150, SR4 Generators and Control Panels Operation and Maintenance ManualSEBU6918, SR4B Generators and Control Panels Operation and Maintenance ManualSENR7337, Service Manual, 3408 and 3408B Industrial and Marine EnginesSENR7405, Service Manual, 3412 Industrial and Marine EnginesSENR2559, Service Manual, 3408 and 3412 Generator Set EnginesSEHS7654, Alignment-General InstructionsSEHS9124, Cleaning and Drying of Caterpillar Electric Set GeneratorsLEBH9324, Agricultural and Material Handling Application and Installation GuideSEHS7292, Use of 5P4150 Nozzle Testing GroupSEHS8622, Using the FT1984 Air-To-Air Aftercooler Leak Test GroupSEHS7795, Use of Pump & Governor Tool GroupSEHS8024, Governor Adjusting Tool GroupSEHS8094, Use of Nozzle Puller GroupAdditional Reference Material
ASTM D2896- TBN MeasurementsASTM D21768- Worked PenetrationASTM D2982B- Ethylene Glycol ContentASTM D3828A- Fuel DilutionASTM D445- ViscosityASTM D893- InsolublesASTM 498589- GM-6038M SpecificationASTM Specs can normally be obtained from your local technological society, library or college.SAE J313- Diesel FuelsSAE J754- NomenclatureSAE J183- ClassificationSociety of Automotive Engineers (SAE) Specs can be found in your SAE handbook or can be obtained from your local library, college, or technological society.* SAE handbooks can be obtained directly from:SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
Engine Manufacturers Association (EMA) information for lube oil selection can be obtained from your local library, college or technological society, or contact:* Engine Manufacturers AssociationLubricating Oils Data Book
401 N. Michigan Ave. Ste. 2400
Chicago, IL 60611
(312) 644-6610 ext. 3626