101441-9810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419810


 

Information injection-pump assembly

ZEXEL 101441-9810 1014419810
101441-9810 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101441-9810 1014419810


Zexel num
Bosch num
Firm num
Name
101441-9810 
 
  DPICO
INJECTION-PUMP ASSEMBLY
C240 * 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
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-3-4-2
Pre-stroke mm   2.25 2.2 2.3
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   12.9
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   39.3 37.7 40.9
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   12
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   38.5 37.5 39.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   -
Rack position   8.8+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   8 6.9 9.1
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Timer adjustment
Pump speed r/min   500+-50
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   1 0.5 1.5
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   2 1.2 2.7
Timer adjustment_04
Pump speed r/min   1200
Advance angle deg.   2.9 2.4 3.4
Timer adjustment_05
Pump speed r/min   -
Advance angle deg.   6 6 6
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101441-9810
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)At rack cap installation: R1 (4)At delivery
----------
K=12 R1=(17.5)mm
----------

Speed control lever angle

Test data 101441-9810
F:Full speed I:Idle (1)At delivery (2)Stopper bolt setting
----------

----------
a=9deg+-5deg b=22deg+-5deg

Stop lever angle

Test data 101441-9810
N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

Test data 101441-9810
(1)Pump vertical direction (2)Gear mark Z for the No. 4 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(60deg)




Information:


When all details are filled in, select "Submit".Note: Two labels and a serial number plate will be sent to the dealer address. If two labels are not received, contact Global_Engine_Marking.
Illustration 27 g03159376
Install the new emissions certification film (6), information label (7), and serial number plate on the cylinder block according to the installation instructions received with the labels and plate.Note: Destroy the old emissions certification film and serial number plate.Operation and Maintenance information
There are several specific messages on this machine. The exact location of the messages and the description of the messages are reviewed in this section. Become familiarized with all messages.Make sure that all of the messages are legible. Clean the messages or replace the messages if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the messages. Loose adhesive will allow the messages to fall.Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Any Cat® dealer can provide new messages.
Illustration 28 g03501777
Location of films (1) Engine Oil film (2) Diesel Fuel Requirements filmEngine Oil (1)
This film is located next to the engine oil filler tube on the right side of the machine.
Illustration 29 g02448560
Cat® DEO-ULS oils and oils that satisfy the "API CJ-4"and/or "ACEA E9" requirements are required for engines that are equipped with a diesel particulate filter.Diesel Fuel Requirements (2)
This film is located next to the fuel cap on the right side of the machine.
Illustration 30 g03619316
Use Ultralow Sulfur Diesel (ULSD) fuel.The Environmental Protection Agency (EPA) defines Ultra-Low Sulfur Diesel (ULSD - S15) as "a diesel fuel with a sulfur content not to exceed 15 parts per million (ppm(mg/kg)) or 0.0015 percent by weight". Engines are equipped with exhaust after-treatment systems are designed to run on ULSD only. Use of LSD or fuels higher than 15 ppm (mg/kg) sulfur in these engines will reduce engine efficiency and engine durability. Damage to the emissions control systems and/or shortened service interval will occur. Failures that result form the use of fuels are not Caterpillar factory defects. Therefore the cost of repairs would not be covered by a Caterpillar warranty.In Europe, ultra low sulfur diesel fuel will have a maximum of 0.0010 percent (10 ppm(mg/kg)) sulfur and is typically referred to as "sulfur-free". This sulfur level is defined in European Standard "EN 590:2004".Lubricant Viscosities - Fluids Recommendations
Engine Oil
Cat® oils have been developed and tested to provide the full performance and life that has been designed and built into Cat® engines.
Illustration 31 g02448560
Cat® DEO-ULS or oils that meet the Cat® ECF-3 specification and the API CJ-4 are required for use in the applications listed below. Cat® DEO-ULS and oils meeting Cat® ECF-3 specification and the API CJ-4 and ACEA E9 oil categories have been developed with limited

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