101405-9021 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014059021

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101405-9021 1014059021

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Cross reference number

ZEXEL 101405-9021 1014059021

Zexel num

Bosch num

Firm num

Name

101405-9021

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 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 1200 1200 1200

Average injection quantity mm3/st. 48 47 49

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.6+-0.5

Pump speed r/min 500 500 500

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 9.4++

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

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
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K=9 N1=1200r/min N2=800r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=7deg+-5deg b=23.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
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a=7deg+-5deg b=53deg+-5deg

Timing setting

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

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

Information:

Your truck may not have the same or all of the gauges as shown in the illustrations. The illustrations shown are of typical gauges.Gauges provide a "look" inside the engine. Be sure they are in good working order. You can determine what is the "normal" operating range by observing your gauges over a period of time.Noticeable changes in gauge readings are indicative of potential gauge or engine problems. This also applies to gauge readings that have changed significantly but are still within specifications. The cause of any sudden or significant change in the readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be between 40 and 88 psi (275 and 606 kPa) when the engine is running at rated engine speed, with SAE 15W-40 oil, at operating temperature. A lower pressure is normal at low idling speed.
If no oil pressure is indicated, stop the engine. Engine damage can result.
Water Temperature - Indicates engine coolant temperture. It should normally indicate between 170°F (77°C) and 208°F (98°C). Somewhat higher temperature may occur under certain conditions. Maximum allowable temperature is 210°F (99°C) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).With the engine running, during normal operation, if the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge, have the charging system checked for malfunction. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding when downshifting, goin downhill, etc., can result in serious damage to your engine.
Do not exceed maximum braking rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. Electrically operated, it registers only when the key switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 23 psi (160 kPa) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of clock hours the engine has operated.