101401-9320 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019320

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9320 1014019320

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Cross reference number

ZEXEL 101401-9320 1014019320

Zexel num

Bosch num

Firm num

Name

101401-9320

DPICO

INJECTION-PUMP ASSEMBLY
4D31T * Q

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 131424-6220

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 3.6 3.55 3.65

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 10.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 54 53 55

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 H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

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(10.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 54 53 55

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 68 64 72

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 37.5 33.5 41.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point D

Rack position (R2+0.15 )

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 28.5 24.5 32.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 67 67 72

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.6

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.5)

Boost pressure kPa 30.7 24 30.7

Boost pressure mmHg 230 180 230

Timer adjustment

Pump speed r/min 1500--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1450

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1750

Advance angle deg. 2.5 2 3

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)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=H93 BCL=0.6+-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=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at delivery) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). Confirm non-injection. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=(8)mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

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=14deg
----------
a=(130deg)

Information:

14May2018
U-275
A-204
D-241
O-246
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 224-4536 CHANGE 06 INJECTION ACTUATION PRESSURE SENSORS FROM DEALER PARTS STOCK
7750 PI70708
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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.
TERMINATION DATE
31Aug2018
PROBLEM
224-4536 change 06 Injector Actuation Pressure Sensor may fail if placed into service.
ACTION REQUIRED
Remove 224-4536 change 06 Injector Actuation Pressure Sensors from dealer parts stock. Image 1 shows a picture of the sensor to remove from the shelves.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.