101402-9480 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029480


 

Information injection-pump assembly

ZEXEL 101402-9480 1014029480
101402-9480 INJECTION-PUMP ASSEMBLY
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Service parts 101402-9480 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-8451
3. GOVERNOR 105419-2290
4. SUPPLY PUMP 105220-7170
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2)
13. NOZZLE-HOLDER
14. NOZZLE
15. NOZZLE SET

Include in #1:

101402-9480 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-9480 1014029480


Zexel num
Bosch num
Firm num
Name
101402-9480 
 
   
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   131424-1520
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   3.6 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   A
Rack position   8.9
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   48.3 47.3 49.3
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   13 12 14
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   65 60 70
Fixing the lever   *
Rack limit   *

Test data Ex:

Governor adjustment

Test data 101402-9480
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=8 N1=1250r/min N2=800r/min
----------

Speed control lever angle

Test data 101402-9480
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=7deg+-5deg b=26deg+-5deg

Stop lever angle

Test data 101402-9480
N:Pump normal S:Stop the pump. (1)At delivery
----------

----------
a=58deg+-5deg b=53deg+-5deg

Timing setting

Test data 101402-9480
(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




Information:

The Primary Engine Checks consist of quick and easy procedures that could identify the problem with a minimum loss of time. Always make these checks before starting the more involved troubleshooting procedures.Whenever a problem is found and corrected, always run the test again to that point to be sure there is not a combination of problems. When the problem has been corrected and the complaint resolved, stop the test. Do not continue through the complete procedure unless it is necessary. Possible Causes/Corrections Prestart ChecksMake sure the air filter elements are in good condition and are not plugged. Also, make sure the engine oil and coolant are at the correct levels. Check Accelerator LinkageTo check the linkage adjustment, push the pedal down until it hits the stop. If the linkage adjustment is correct, the governor linkage will move to the break-over position when the pedal is against the stop. This is shown by clearance on both sides of the tang (see the illustration). When there is clearance on both sides of the tang, the governor linkage is adjusted correctly to permit the engine to operate at high idle. If clearance is not present on both sides of the tang, adjust the governor linkage to give the needed clearance.
Governor Control Linkage Adjustment
(1) Clearance on both sides of tang. (2) Governor control linkage. (3) Pedal (full travel). (4) Governor control. (5) Lever assembly. Check Vehicle TachometerInstall the 6V3121 Multitach Group. Start the engine and make sure that the vehicle tachometer is accurately indicating engine rpm. Some electric vehicle tachometers can be adjusted. Correct the tachometer as required. A defective tachometer can cause operation at the wrong engine rpm, this can give the feel of low power. Check For Air In The FuelDisconnect the fuel return line. With the engine in operation, let the fuel from the injection pump housing flow into a container. Look for air bubbles in the fuel coming from the return line. Approximately 5 to 100 visible air bubbles in the fuel is normal. If there is excessive air in the fuel find the cause and correct it. Such as checking all fuel lines and connections for leaks and repair or replacement of parts as needed. Check Fuel API Gravity RatingCaterpillar diesel engines are set in production to produce rated power with a fuel of 35 API gravity (0.85 specific gravity). This limit provides a grade of fuel that aids engine starting and avoids vapor lock. Fuel with higher API gravities (i.e., lower specific gravities), will produce less horsepower at the factory power setting and vice versa for lower than 35 API gravity fuels. The engine fuel setting should not be adjusted to compensate for a power loss with fuels lighter than 35 as fuel system component life may be decreased.For more information see Special Instruction Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables. Check For Proper Fuel Heater ApplicationMake sure that fuel heaters are

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Group cross 101402-9480 ZEXEL

Yanmar 

9 400 610 491 
 
INJECTION-PUMP ASSEMBLY
4TNE98
9 400 610 492 
 
INJECTION-PUMP ASSEMBLY
4TNE98
 
 
INJECTION-PUMP ASSEMBLY

Yanmar 

9 400 613 330 
12995051000 
INJECTION-PUMP ASSEMBLY
4TNE98
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
4TNE94
 
 
INJECTION-PUMP ASSEMBLY

Yanmar 

9 400 612 817 
12990051000 
INJECTION-PUMP ASSEMBLY
4TNE94
9 400 613 180 
12990051001 
INJECTION-PUMP ASSEMBLY
4TNE94
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Yanmar 

9 400 614 013 
12998251000 
INJECTION-PUMP ASSEMBLY
4TNE98
 
 
INJECTION-PUMP ASSEMBLY
4TNE94
9 400 614 014 
 
INJECTION-PUMP ASSEMBLY
4TNE94

Mitsubishi-Heav 

9 400 610 493 
3426102060 
INJECTION-PUMP ASSEMBLY
S4K-EIT
9 400 611 419 
3426102061 
INJECTION-PUMP ASSEMBLY
S4K-EIT
9 400 610 494 
3426102080 
INJECTION-PUMP ASSEMBLY
S4K-T
9 400 611 680 
3426102081 
INJECTION-PUMP ASSEMBLY
S4K-T
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
4TNE94

Yanmar 

9 400 612 522 
12991551000 
INJECTION-PUMP ASSEMBLY
4TNE94
9 400 613 093 
12991551001 
INJECTION-PUMP ASSEMBLY
4TNE94
101402-9480  
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Yanmar 

 
 
INJECTION-PUMP ASSEMBLY
4TNE94
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Yanmar 

 
12995551000 
INJECTION-PUMP ASSEMBLY
4TNE98
9 400 614 015 
12995551001 
INJECTION-PUMP ASSEMBLY
4TNE98
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