101441-9861 ZEXEL 9 400 619 646 BOSCH INJECTION-PUMP ASSEMBLY 9400619646 1014419861

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 646 9400619646

ZEXEL 101441-9861 1014419861

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Buy INJECTION-PUMP ASSEMBLY 101441-9861 zexel genuine, new aftermarket engine parts with delivery

Service parts 101441-9861 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8300

3. GOVERNOR 105410-9961

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS 105622-1900

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105148-1121

11. Nozzle and Holder 1660043G03

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105078-0050

14. NOZZLE

105007-1130

15. NOZZLE SET

Include in #1:

101441-9861 as INJECTION-PUMP ASSEMBLY

106672-4712 as _

Cross reference number

BOSCH 9 400 619 646 9400619646

ZEXEL 101441-9861 1014419861

Zexel num

Bosch num

Firm num

Name

101441-9861
101441-9862

9 400 619 646

INJECTION-PUMP ASSEMBLY
* K

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 2.15 2.1 2.2

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 12.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 45.5 44.5 46.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.9

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 45.1 43.6 46.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 55 50 60

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 3.5 3 4

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 6.6 6.1 7.1

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 7.3 7.3 7.3

Remarks
Measure the actual speed, stop

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
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=36deg+-5deg b=31deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=7.6mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=1000r/min r2=1000r/min r3=1000r/min r4=- r5=- r6=- Q1=- Q2=45.5+-1mm3/st Q3=- Q4=- Q5=- Q6=- c1=- c2=+-4% c3=- c4=- c5=- c6=- a7=36 a8=35 a9=34 a10=33 a11=32 a12=31 a13=30 a14=29 a15=28 a16=27 a17=26 a18=25 a19=24 a20=23 a21=22 a22=21 a23=20 a24=- a25=- a26=- a27=- a28=- r7=1800r/min r8=1750r/min r9=1700r/min r10=1650r/min r11=1600r/min r12=1550r/min r13=1500r/min r14=1450r/min r15=1400r/min r16=1350r/min r17=1300r/min r18=1250r/min r19=1200r/min r20=1150r/min r21=1100r/min r22=1050r/min r23=1000r/min r24=- r25=- r26=- r27=- r28=- R7=1935+-45r/min R8=1880+-43r/min R9=1825+-42r/min R10=1770+-41r/min R11=1720+-40r/min R12=1665+-38r/min R13=1610+-37r/min R14=1555+-36r/min R15=1505+-35r/min R16=1450+-33r/min R17=1395+-32r/min R18=1340+-31r/min R19=1290+-30r/min R20=1235+-28r/min R21=1180+-27r/min R22=1130+-26r/min R23=1075+-25r/min R24=- R25=- R26=- R27=- R28=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(100deg)

Information:

Illustration 1 g00656709
(1) Error code (2) Activity on CAT Data Link (3) First digit of error code (4) The CCM is transmitting on RS 232C. (5) Second digit of error code (6) The CCM is receiving data on the RS 232C.The values E, 0, and 0 indicate an error code of 00. The code E00 means that no faults are present, and the CCM is in normal operating mode. The complete list of error codes are in the Operation and Maintenance Manual, "Troubleshooting" section. The periods on the display will flash when information is transmitted on the CAT Data Link. The periods on the display will flash when information is transmitted on the RS-232C port. No period indicates that no activity is taking place.Note: Units with the part number 117-6170 Customer Communication Module will display the faults that have been logged. Each fault will be displayed for 2 seconds in 60 second intervals. This flashing fault log will not appear for any other version of CCM. The fault log can be cleared by using the PC software for the CCM.CCM Power Up Display
The CCM display will perform a lamp test (8.8.8.). The parameters for communication protocol (n81 9600 E00) will be displayed next. An example of the power up sequence is given below:
Table 1
8.8.8. n81 9600 E00
8.8.8. All of the segments are turned on for a two second lamp test.
n81
n
8
1 No parity (default value)
Eight data bits (default value)
One stop bit (default value)
9600 Rate of Communication (default value)
E00 Error Code
No faults are present. The values for communication can be changed by using a host device or by using the PC software for the CCM. Refer to "Caterpillar CCM PC For Windows: Getting Started Manual". The values for communication must match the values for the modems (if used) and the values for the host device.