101401-9340 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019340

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9340 1014019340

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Cross reference number

ZEXEL 101401-9340 1014019340

Zexel num

Bosch num

Firm num

Name

101401-9340

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

0000001501 ACTUATOR

(a) Screw (B) Nut Bolt c (d) Speed lever (e) Actuator shaft 1. Actuator adjustment procedure (1)Position the speed lever (d) in the idle position. (2)Set bolt (c) so that the clearance between the speed lever (d)'s pin and the actuator shaft (e) is approximately L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1 and read the rack position when negative pressure P1 is applied to the actuator. (5)Gradually loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Apply negative pressure several times and confirm that the lever (d) returns to the idle position at negative pressure '0.' (7)Confirm that rack position is R2 when negative pressure is P2.
----------
L1=2mm N1=500r/min P1=66.7kPa(500mmHg) N2=500r/min R1=9.1mm P2=66.7kPa(500mmHg) R2=9.1mm
----------

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:

PARTS NEEDED
Qty
Part Number Description
1 6V8260 SEAL-O-RING
1 2147567 SEAL-O-RING-STOR
1 2147568 SEAL-O-RING-STOR
1 2287102 SEAL-O-RING-STOR
1 2842728 SENSOR GP-PRESS
1 2953099 PLUG-SPARK
1 2986488 SENSOR GP-PRESS
1 3003556 VALVE GP-SOL
1 3278044 VALVE GP-CHECK-A
2 3483425 GASKET
1 3790150 PUMP GP-FUEL
1 4154991 VALVE AS-RELIEF
1 4286096 KIT-F PUMP LINE
1 4333677 HEAD AS-COMB
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 31% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
1. Refer to Special Instruction, REHS5023, "Replacing the Fuel Injection Pump on Certain C9.3 Engines". Replace the existing 375-5244 common rail fuel injection pump with the 379-0150 common rail fuel injection pump and new gasket 6V-8260. Install a new 356-5214 fuel line from the common rail fuel injection pump to the fuel rail.
2. Refer to C9.3 Disassembly and Assembly, KENR8149 "Engines for Caterpillar Built Machines". Replace the prior 362-0770 common rail pressure relief valve with 415-4991 Pressure Relief Valve, and 228-7102 O-ring.
3. Replace the ARD manifold pilot and main fuel pressure sensors with 284-2728 Main Pressure Sensor and 214-7567 O-ring. Repeat the same procedure with the Pilot Pressure Sensor 298-6488 and 214-7568 O-ring.
4. Replace the 300-3556 Fuel Priming Pump Solenoid and replace the 327-8044 Fuel Priming Pump Check Valve.
5. Replace the existing ARD head with a 433-3677 Combustion Head and (2) 348-3425 Gaskets. Install a new 295-3099 Spark Plug.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-4000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-6000 hrs,
25-36 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 26.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.