101401-9770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019770

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9770 1014019770

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Cross reference number

ZEXEL 101401-9770 1014019770

Zexel num

Bosch num

Firm num

Name

101401-9770

INJECTION-PUMP ASSEMBLY

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 134424-4120

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 3.2 3.15 3.25

Rack position
Point A R=A

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 14.6

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 108.5 106.9 110.1

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 13 11.2 14.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(14.6)

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 108.5 107.5 109.5

Basic *

Fixing the lever *

Boost pressure kPa 70.6 70.6

Boost pressure mmHg 530 530

Injection quantity adjustment_04

Adjusting point B

Rack position R1-1.05

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 88 84 92

Fixing the lever *

Boost pressure kPa 70.6 70.6

Boost pressure mmHg 530 530

Injection quantity adjustment_05

Adjusting point C

Rack position R2-0.95

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 58 54 62

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-0.95

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-1. 35)

Boost pressure kPa 57.3 57.3 57.3

Boost pressure mmHg 430 430 430

Timer adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1550

Advance angle deg. 5.1 4.6 5.6

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 7 6.5 7.5

Remarks
Measure the actual speed, stop

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)Boost compensator stroke: BCL
----------
T1=L33 BCL=0.95+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=71deg+-5deg b=(38deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg

0000001501 LEVER

(A) Speed lever (lower) (B) Stopper bolt (C) Special lever (upper) a:Point A (inside lever) 1. Special lever adjustment (1)With the speed lever at the idle position, set the accelerator lever stopper bolt so that the accelerator lever contacts the speed lever at point a. (2)Back off the stopper bolt L and set.
----------
L=1+0.5mm
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0000001601 POTENTIO METER

(A) : Governor plan view (B): Potentiometer harness terminal (C): Potentiometer connection diagram (D) : Output voltage standard value (S): Voltage P/M: potentiometer (v): output voltage (V) (p): direction of potentiometer rotation 1. Adjustment procedures (1)Apply DCV1 to potentiometer harness terminal (B) to obtain the specified output voltage. (2)Fix the speed lever at the full side. (3)Loosen the bolt (S), and move the potentiometer from left and right. (4)Adjust so that the output voltage at full is within the standard values. (5)Fix bolt (S). (6)Repeatedly move the speed lever from the full side to the idle side. (7)Check that it is within the standard values at full and idle.
----------
V1=5+-0.02V
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V1=5+-0.02V Va=(5)V Vb=(3.75)+-0.2V Vc=0.58+-0.3V

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=5deg
----------
a=(50deg)

Information:

Table 4 is an example for using the equation that is in Table 3.
Table 4
Example of the Equation for the Addition of Cat SCA To Water For Maintenance
Total Volume of the Cooling System (V) Multiplication
Factor Amount of Cat SCA that is Required (X)
946 L
(250 US gal) × 0.023 22 L
(6 US gal) Note: Specific engine applications may require maintenance practices to be periodically evaluated to maintain the engine cooling system properly.Cleaning the System of Heavy-Duty Coolant/Antifreeze
Before Cat SCA can be effective, the cooling system must be free from rust, scale, and other deposits. Preventive cleaning helps avoid downtime caused by expensive out-of-service cleaning required for extremelydirty and neglected cooling systems.Cat Cooling System Cleaners
Dissolves or depresses mineral scales, corrosion products, light oil contaminations, and sludges
Cleans the cooling system after used coolant is drained or before the cooling system is filled with new coolant
Cleans the cooling system whenever the coolant is contaminated or whenever the coolant is foaming
The “Standard” version of the Cat Cooling System Cleaners clean the cooling system while still in service.
Reduces downtime and cleaning costs
Helps avoid costly repairs from pitting and other internal problems caused by improper cooling system maintenance
Can be used with glycol-based antifreeze
For the recommended service interval, refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule" for your engine.Cat Standard Cooling System Cleaners are designed to clean the cooling system of harmful scale and corrosion without removing the engine from service. The cleaners, both “Standard” and “Quick Flush” can be used in all Cat engine cooling systems. Consult your Cat dealer for part numbers.Note: These cleaners must not be used in systems that have been neglected or that have heavy scale buildup. These systems require a stronger commercial solvent that is available from local distributors.Prior to performing a cleaning of the cooling system, take a 1-liter (1-quart) sample of coolant from the engine while in operation into a clear container. Take the sample shortly after start-up while the coolant is not yet hot. The coolant should be adequately mixed by the water pump. Allow the sample