101401-9442 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019442 tf7013800a


 

Information injection-pump assembly

ZEXEL 101401-9442 1014019442
MAZDA TF7013800A tf7013800a
101401-9442 INJECTION-PUMP ASSEMBLY
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Service parts 101401-9442 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-9051
3. GOVERNOR 105921-8241
4. SUPPLY PUMP 105210-6240
5. AUTOM. ADVANCE MECHANIS 105671-0480
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-6101
11. Nozzle and Holder TF70 13 H50A
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-3450
14. NOZZLE 105017-1970
15. NOZZLE SET

Include in #1:

101401-9442 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101401-9442 1014019442
MAZDA TF7013800A tf7013800a


Zexel num
Bosch num
Firm num
Name
101401-9442 
101401-9443 
 
TF7013800A  MAZDA
INJECTION-PUMP ASSEMBLY
TF * K

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   131424-9020
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   3.8 3.75 3.85
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   13
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   74.5 74 75
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.   8.5 6.5 10.5
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)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   74.5 74 75
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.05
Pump speed r/min   1625 1625 1625
Average injection quantity mm3/st.   87 83 91
Fixing the lever   *
Timer adjustment
Pump speed r/min   1000
Advance angle deg.   0.5 0 1
Timer adjustment_02
Pump speed r/min   1600
Advance angle deg.   6.5 6 7
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9442
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=L02
----------

Speed control lever angle

Test data 101401-9442
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=20deg+-5deg b=(40deg)+-3deg

Stop lever angle

Test data 101401-9442
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=26deg+-5deg

0000001501 LEVER

Test data 101401-9442
CL:Center line of camshaft ST:Stop adjuster screw f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever 1. Stop lever adjustment outline (1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position. (2)Set the speed lever in the full speed position. (3)At pump speed Na, position the rack at non-injection position Ra. (4)Set the stop adjusting screw to fix the speed lever in the idling position. (5)Confirm that there is no injection at pump speed Nb.
----------
Na=1965r/min Nb=325r/min Ra=6.5+-0.3mm
----------

0000001601 RACK SENSOR

Test data 101401-9442
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=1325r/min Ra=R1(13)+0.75mm Vist=3.05+-0.28V
----------

Timing setting

Test data 101401-9442
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(140deg)




Information:


15Jun2015
(Revised 08Sep2015)
U-312
A-215
D-253
O-261
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 10R4761 AND 10R4763 REMAN INJECTORS FROM DEALER PARTS STOCK
7750 PI70569
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.
This Revised Service Letter replaces the 15Jun2015 (Revised 12Aug2015) Service Letter. Changes have been made to Action Required and Service Claim Allowance. A request for photographs to be submitted with the claims story has been added.
TERMINATION DATE
30Sep2015
PROBLEM
Certain reman fuel injectors were mislabeled with an incorrect part number.
ACTION REQUIRED
Inspect all 10R4761 and 10R4763 Reman Fuel Injectors in dealer parts stock.
If an injector has a 12-character serial number listed in the table in Image 1, remove the part from dealer parts stock. Refer to the Parts Disposition. Include the Injector Serial Number in the Claim Story. Also, attach a photograph of the injector serial number with the claim story.
If an injector does not have a 12-character serial number listed in the table in Image 1, mark the package to indicate that the part has been inspected according to this program and return the part to dealer parts stock.
Image 2 identifies Reman Hydraulic Electronic Unit Injector (HEUI) product markings.
(1) 7-character Part Number
(2) 12-character Serial Number
(3) 4-digit Confirmation Code
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock. Include the Injector Serial Number(s) in the Claim Story. Also, attach a photograph of the injector serial number with the claim story.
PARTS DISPOSITION
NACD:
Hold all 10R4761 and 10R4763 Reman Fuel Injectors removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
EAME, LACD, and APD:
Hold all 10R4761 and 10R4763 Reman Fuel Injectors removed from dealer parts stock for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
Contact Runge_Mark_H at Reman Product Support for a Parts Return Request (PRR).
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

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Group cross 101401-9442 ZEXEL

Mazda 

 
TF7013800 
INJECTION-PUMP ASSEMBLY
TF
 
 
INJECTION-PUMP ASSEMBLY

Mazda 

101401-9442  

101401-9443 
 
TF7013800A 
INJECTION-PUMP ASSEMBLY
TF
 
TF7013800B 
INJECTION-PUMP ASSEMBLY
TF
 
TF7013800F 
INJECTION-PUMP ASSEMBLY
TF
 
TF7013800G 
INJECTION-PUMP ASSEMBLY
TF
 
TF7013800H 
INJECTION-PUMP ASSEMBLY
TF
F 01G 09U 017 
 
INJECTION-PUMP ASSEMBLY

Mazda 

9 400 613 803 
TF7013800J 
INJECTION-PUMP ASSEMBLY
TF
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