101441-9871 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419871

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101441-9871 1014419871

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Cross reference number

ZEXEL 101441-9871 1014419871

Zexel num

Bosch num

Firm num

Name

101441-9871

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

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 -

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_03

Adjusting point C

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 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 3.5 3 4

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)Rack difference between N = N1 and N = N2
----------
K=15 N1=1270r/min N2=750r/min
----------

Speed control lever angle

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

----------
a=25deg+-5deg b=18deg+-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
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a1=A a2=B a3=C a4=- r1=1000r/min r2=1000r/min r3=1000r/min r4=- Q1=- Q2=45.5+-1mm3/st Q3=- Q4=- c1=- c2=+-4% c3=- c4=- a5=26 a6=25 a7=24 a8=23 a9=22 a10=21 a11=20 a12=19 a13=18 a14=17 a15=- r5=1300r/min r6=1250r/min r7=1200r/min r8=1150r/min r9=1100r/min r10=1050r/min r11=1000r/min r12=950r/min r13=900r/min r14=850r/min r15=- R5=1395+-32r/min R6=1340+-31r/min R7=1290+-30r/min R8=1235+-28r/min R9=1180+-27r/min R10=1130+-26r/min R11=1075+-25r/min R12=1020+-23r/min R13=965+-22r/min R14=915+-22r/min R15=-

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:

Remote Fault Reset$00 $0D aUsed to reset faults on the CCM.
Table 2
(a) $00 - $7F = Retain current CCM inactive fault status.
$80 - $FF = Reset CCM inactive fault. Device ID Code$00 $80 aabbccUsed to read the device ID code from the CCM as well as other components on the data link. Each pair of bytes (aa, bb, cc) is sent LSB first.
Table 3
(aa) Module ID: will always equal $61, data will be sent as $61 $00
(bb) Service Tool Support Change Level: $01, data will be sent as $01 $00
(cc) Application type:$FF $E0, data will be sent as $E0 $FF CCM Error Codes$00 $82 abUsed to read the CCM Error Codes.
Table 4
(a) bit 1 = Reserved
(b) (1) Fault Code Status
bit 8 1 = RS-232C link message fault exists
bit 7 1 = Miscellaneous Cat Data Link fault
bit 6 1 = Invalid Cat Data message fault
bit 5 1 = Internal buffer overflow on RS-232C or Data Data Link fault
bit 4 1 = RS-232C short circuit fault
bit 3 1 = Memory battery is weak
bit 2 1 = M5X message error (checksum or byte count error)
bit 1 1 = EEPROM fault
( 1 ) A value of 0 (zero) in bits 1 through 8 indicates that particular fault does not exist.CCM Communication Rate Change Enable$AA $12 aUsed to determine if the CCM is connected to the host computer directly or remotely using a modem. Also used to enable or disable the host computers ability to change the communication rate of the RS-232C serial port.
Table 5
(a) Bit 4 Reserved for Caterpillar.
Bit 3 0 = Enable password protection
1 = Disable password protection
Bit 2 0 = Enable baud rate change
1 = Disable baud rate change
Bit 1 0 = Direct connection
1 = Modem connection Access Level 1 Password$AA $87 aaaaaaaaUsed to read or program the Level 1 Password
Table 6
(aaaaaaaa) Level 1 password in printable ASCII form. Must be at least 6, but no more than