101401-7010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014017010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-7010 1014017010

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Service parts 101401-7010 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8330

3. GOVERNOR 105932-0890

4. SUPPLY PUMP 105210-6170

5. AUTOM. ADVANCE MECHANIS 105676-8050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6041

11. Nozzle and Holder 8-97119-811-0

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

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE

105017-1850

15. NOZZLE SET

Include in #1:

101401-7010 as INJECTION-PUMP ASSEMBLY

101402-2181 as _

Cross reference number

ZEXEL 101401-7010 1014017010

Zexel num

Bosch num

Firm num

Name

101401-7010

INJECTION-PUMP ASSEMBLY
14BD PE4AD PE

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 131424-3920

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 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 11.1

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 66.9 70.1

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 9.5+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 10.5 9.2 11.8

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(11.1)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 67.5 69.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 89.5 85.5 93.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 520 520 520

Average injection quantity mm3/st. 47.6 43.6 51.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.15

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 76 72 80

Fixing the lever *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 6 6 6.5

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=N20
----------

Speed control lever angle

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

----------
a=43deg+-5deg b=42deg+-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=400r/min Ra=9.3+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

0000001601 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=960r/min Ra=R1(11.1)mm Vist=2.33+-0.28V
----------

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=7deg
----------
a=(60deg) b=(85deg)

Information:

Lubricants, Coolants, and Greases
Data sheets, specifications, and recommendations for Cat lubricants, coolants, and greases are available through your Cat dealer and at the following website:http://parts.cat.com/parts/machine-fluids
Special Publication, PEWJ0074, "Filters and Fluids Application Guide"
Special Publication, PEHJ0149, "Cat Filters and Fluids Toolbox Update - Datasheet Set"
Special Publication, REHS1063, "Know Your Track-Type Tractor Cooling System"
Special Publication, SEBD0518, "Know Your Cooling System"
Special Publication, PEGJ0035, "Grease Selection Guide"Fuel
Special Publication, PEHP7046, "Fuel Contamination Control Data Sheet"
Special Publication, SENR9620, "Improving Fuel System Durability"
Special Publication, SEBD0717, "Diesel Fuels and Your Engine"
"ASTM D6751 Standard Specification for Biodiesel Fuel Blend Stock (B100) for Middle Distillate Fuels"
"EN 14214 Automotive fuels - Fatty acid methyl esters (FAME) for diesel engines - Requirements and test methods"
"ASTM D7467 Standard Specification for Diesel Fuel Oil, Biodiesel Blend (B6 to B20)"
"ASTM D975 Standard Specification for Diesel Fuel Oils" (includes requirements for B5 and lower biodiesel blends)
"EN 590 Automotive fuels - Diesel - Requirements and test methods" (includes requirements for B5 and lower biodiesel blends)
"EN 14078 Liquid petroleum products - Determination of fatty acid methyl esters (FAME) in middle distillates - Infrared spectroscopy method"
"EN 14104 Fat and oil derivatives - Fatty Acid Methyl Esters (FAME) - Determination of Acid Value"
"ASTM D664 Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration"
"ASTM D6469 Standard Guide