101441-9890 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419890


 

Information injection-pump assembly

ZEXEL 101441-9890 1014419890
101441-9890 INJECTION-PUMP ASSEMBLY
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Service parts 101441-9890 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101044-9150
3. GOVERNOR 105419-1001
4. SUPPLY PUMP 105220-6270
5. AUTOM. ADVANCE MECHANIS 105621-0450
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:

101441-9890 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101441-9890 1014419890


Zexel num
Bosch num
Firm num
Name
101441-9890 
 
  DPICO
INJECTION-PUMP ASSEMBLY
DC24 * 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 101441-9890
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK CAP: R1 (4)At delivery
----------
K=12 R1=(17.5)mm
----------

Speed control lever angle

Test data 101441-9890
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101441-9890
N:Pump normal S:Stop the pump. (1)Normal
----------

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

Timing setting

Test data 101441-9890
(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:


Illustration 1 g00669441
CCM to Host Equipment Direct Connection (1) CCM (2) CCM RS-232C port (3) Computer RS-232C port (4) Host equipmentMake sure that the following equipment is available:
A personal computer. Refer to "Caterpillar CCM PC For Windows: Getting Started Manual" for specifications on the PC.
The proper RS-232C cables are required for the particular installation. Refer to the Operation and Maintenance Manual, "RS-232C Cable Requirements".
The CCM PC Software for Windows. This software is available from Caterpillar.ProcedurePerform the following procedure to initialize communication with the host equipment that is connected directly to the CCM.Note: The host equipment and the CCM should be turned OFF before you change the cables to the serial ports.
The CCM should be installed with all of the wiring. Refer to Operations and Maintenance Manual, "General Wiring Diagram" and "RS-232C Cable Requirements".
Determine the parameters for communication for the installation. The default rate of communication (bits per second or bps) is 9600. The remaining default settings from the factory are no parity, 8 data bits, and 1 stop bit. These parameters will work well in most installations. Use the Operations and Maintenance Manual, "Communication Parameters - Identify" to determine the parameters of communication that are stored in the CCM.
Load the CCM PC For Windows software into the PC. Refer to the "Caterpillar CCM PC For Windows: Getting Started Manual". Start the CCM PC program and connect to the CCM.
Go to the Data Link pull-down menu. Select ECM, CCM. Go to the CCM configuration screen in the Utilities menu. Set the parameters for communication to match the values that were chosen in step 2.
Use the CCM configuration screen to set the Connection Type to Direct Connection. The CCM is now set at the determined communication configuration.Note: If the PC is required to communicate with the CCM, go to the Phone Book pull-down menu and select Add or Edit. Set the communication parameters of the PC to the values that were chosen in Step 2.Note: The electronic controller of each engine must be programmed with the correct engine number for identification on the CCM. The electronic controller is programmed to Engine Number 1 at the factory. Refer to Operation and Maintenance Manual, SEBU6874, "Engine Number - Program".Note: After the CCM has been connected to the PC, refer to the "CCM PC Software Users Manual". This manual contains instructions on monitoring and on controlling the engine remotely.Note: Two conditions must be met before the electronic engine controller will allow control by the CCM. The Engine Control Switch must be in the AUTO position, and the remote initiate contacts must be open. The engine may be monitored with the ECS in any position.Note: For an EMCP II application, the CCM cannot control the generator set if the GSC is in Service Mode. The generator set can only be monitored.

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Group cross 101441-9890 ZEXEL

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Daewoo 

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INJECTION-PUMP ASSEMBLY
DC24
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