Information injection-pump assembly
ZEXEL
101443-9050
1014439050
Rating:
Cross reference number
ZEXEL
101443-9050
1014439050
Zexel num
Bosch num
Firm num
Name
101443-9050
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
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.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
C
Rack position
13.4++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
50
45
55
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
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
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
----------
----------
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
----------
----------
a=25deg+-5deg b=18deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=12deg+-5deg b=53deg+-5deg
----------
----------
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=- 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=-
----------
L=7.6mm
----------
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)
----------
aa=16deg
----------
a=(100deg)
Information:
Connect cable (2) to the RS-232 serial port of PC (1) .
Connect cable (2) to communication adapter (3) .
Connect cable (4) to communication adapter (3) .
Connect cable (4) to the service tool connector on the engine mounted CIP.
Turn the engine control switch to the LOCAL position or to the REMOTE position. Turn the fuel control switch to the FUEL OFF position. The engine should be OFF.If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, RENR5910, "Electronic Service Tool Will Not Communicate With ECM".Troubleshooting
Refer to Troubleshooting, RENR5084 for more information on the following components.
Sensor faults
Injector faults
Response checks for the throttle input
Shutdown input response checksRequirements for the Electrical System
When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through a metal conduit. Use a rigid conduit or a use flexible conduit. A liquid tight conduit is recommended. Use proper support and alignment in order to avoid strain on the conduit.Electronic Service Tools
Caterpillar Electronic Service Tools are designed to help the service technician:
Obtain data.
Diagnose problems.
Read parameters.
Program parameters.
Calibrate sensors.The tools that are listed in Table 12 are required in order to enable a service technician to perform the electrical installation procedures and the initial start-up.Note: Other tools that are needed for measuring operating parameters such as pressure and temperature are not listed in Table 12.
Table 12
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) This PC configuration is recommended:
Intel Pentium II 333 mHz processor
64 megabyte of RAM
4.3 GB hard drive
Drive for floppy disks (3.5 inch with 1.44 MB)
14X speed CD-ROM drive
VGA monitor or display
RS-232 port with 16550AF UART
Windows NT 4.0 (1)
Windows 95 (1)
Windows 98 (1)
Mouse
N/A Personal Computer (PC) This PC configuration has the minimum requirements:
IBM PC compatible 100 MHz processor
32 megabyte of RAM
10 MB of available hard drive space
CD-ROM drive
Drive for floppy disks (3.5 inch with 1.44 MB)
Windows NT 4.0 (1)
Windows 95 (1)
Windows 98 (1)
RS-232 port with 16550AF UART
VGA monitor or display
Mouse
"JERD2124" Software Single user license for Caterpillar Electronic Technician (Cat ET)
Use the most recent version of this software.
"JERD2129" Software Data subscription for all engines
171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (ET) and the ECM.
196-0055 Serial Cable As This cable connects the PC to the 171-4401 Communication Adapter II .
7X-1414 Data Link Cable As This cable connects the service tool connector on the engine mounted junction box to the 139-4166 Adapter Cable As .
8T-8726 Adapter Cable As This breakout t is for use between the jacks and the plugs of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with
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101443-9050
INJECTION-PUMP ASSEMBLY