101401-9591 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019591

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9591 1014019591

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Cross reference number

ZEXEL 101401-9591 1014019591

Zexel num

Bosch num

Firm num

Name

101401-9591

DPICO

INJECTION-PUMP ASSEMBLY
K-1 * 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 131424-5620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.9 3.85 3.95

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 11.5+-0. 5

Pump speed r/min 1000 1000 1000

Each cylinder's injection qty mm3/st. 60 58.5 61.5

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 300 300 300

Each cylinder's injection qty mm3/st. 15 12.7 17.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60 59 61

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 56 52 60

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 39.6 35.6 43.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 80

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1700

Advance angle deg. 5.5 5 6

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
----------
T1=L56
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=40mm
----------
a=26deg+-5deg b=(42deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. Confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed dd. (Rack position = ee or less) (4)Non-injection rack position (5)Rack position corresponding to ff (6)Free (at delivery)
----------
aa=40mm bb=1750r/min cc=(6.2)-0.5mm dd=300r/min ee=(8)mm ff=16mm
----------
a=25deg+-5deg b=20deg+-5deg c=35deg+-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=9deg
----------
a=(130deg)

Information:

TECHNICAL INFORMATION BULLETIN JAN. 15th, 2003
EXCAVATORS
WHEEL LOADERS
ENGINES 322C: (EMR, MAR);
325C: (CRB, CSJ, JLC, JLD, DTF)
950G II: (AYL, AYB);
962G II: (AYE, BAB)
3126B: (BMA)
Component Code(s) 1408SUBJECT: A NEW INJECTION ACTUATION PRESSURE CONTROL VALVE CONNECTOR INCREASES ENGINE OPERATION
PROBLEM:
The injection actuation pressure (IAP) control valve connector may have been assembled incorrectly on some 3126B engine harnesses. This can lead to intermittent engine operation or can cause the engine to stop.
SOLUTION:
If your machine exhibits symptoms of intermittent engine operation or abruptly stopping, the IAP control valve connector should be disconnected from the machine, examined for solenoid contact problems and re-installed using a correct procedure.
Procedure for installing the IAP control valve connector
This procedure will describe how to properly install the 232-4367 Harness.
Required Parts
Qty Part Number Description
1 232-4367 Harness
Procure the part that is listed in the table.
Illustration 1. Left Side of a 3126B Engine on a D6N.
(1) IAP Control Valve
(2) IAP Control Valve Connector
Note: Illustration 1 is from a D6N that is equipped with a 3126B for photographical purposes. The location of the IAP Control Valve is the same for your machine.
Disconnect the IAP control valve connector (2) from the IAP Control Valve (1). See Illustration 1.
Cut the two wires directly behind the connector.
Using wire strippers, strip the ends of the two wires.
Install the 232-4367 Harness, by crimping the stripped wires inside the splice.
Note: Take care to connect the pink wire to the pink wire on one hand and the purple wire to the purple wire on the other hand.
Heat both heat shrinkable tubes in order to insulate both the splices.
Reconnect the repaired harness to the IAP Control Valve (1).
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ALL RIGHTS RESERVED