Information injection-pump assembly
ZEXEL
101491-9354
1014919354
MAZDA
SL7313800B
sl7313800b

Rating:
Service parts 101491-9354 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
SL70 13 H50A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-9354
1014919354
MAZDA
SL7313800B
sl7313800b
Zexel num
Bosch num
Firm num
Name
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
Overflow valve
134424-3420
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
3.4
3.35
3.45
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
-
Rack position
10.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
50.1
49.6
50.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H'
Rack position
9.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9
7
11
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.8)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
50.1
49.6
50.6
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.05
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
36.5
34.5
38.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.28
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
59.1
57.1
61.1
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
91
81
96
Fixing the lever
*
Rack limit
*
Injection quantity adjustment_07
Adjusting point
H
Rack position
9.3+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
7
6.5
7.5
Fixing the rack
*
Timer adjustment
Pump speed
r/min
1350+-25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
3.1
2.8
3.4
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
3.3
3
3.6
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=D09
----------
----------
T1=D09
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.3)mm bb=325r/min
----------
a=20deg+-5deg b=(41deg)+-3deg
----------
aa=(9.3)mm bb=325r/min
----------
a=20deg+-5deg b=(41deg)+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Normal
(2)Stop
(3)Stopper bolt setting
(4)Set the speed to aa using the idle lever and then confirm non-injection.
----------
aa=325r/min
----------
a=(15deg)+-5deg b=(13.5deg) c=23deg+-5deg d=40deg+-5deg
----------
aa=325r/min
----------
a=(15deg)+-5deg b=(13.5deg) c=23deg+-5deg d=40deg+-5deg
0000001501 LEVER

f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
Stop lever's normal position setting method
1. (1) Push in the set bolt (A) until the rack starts to move.
(2)Return the bolt N1 turns from that position and set.
2. Rack with limiter
(1)Return the bolt N1 turns from the rack limit position and set.
----------
N1=1.5
----------
----------
N1=1.5
----------
Timing setting

(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg-2deg
----------
a=(130deg)
----------
aa=14deg-2deg
----------
a=(130deg)
Information:
When the preset temperature, pressure or fluid level occurs, either a light or an audible alarm will be energized. The light or alarm will continue to operate until the condition is corrected. When the condition is corrected the alarm will automatically reset and the light will turn off.
The cause of the shutdown must be investigated and corrected before starting and operating the engine.
Testing Indicator Lights
Most control panels are equipped with a test switch. By turning the switch ON, all of the indicator lights can be checked for proper operation. Test the indicator lights periodically, replace burned out light bulbs immediately.Alarm Shutoff Switch
A switch may be installed in the alarm circuit for silencing the alarm while the engine is stopped for repairs. Be sure the switch is moved to the closed (ON) position and the warning lights are lit before starting.
Place switch in the closed (ON) position when the engine is started, so the engine will be protected.
Output Shaft Governor Operation
When the load can overspeed the torque converter output shaft, an output shaft governor should be installed. The output shaft governor is a speed limiting device which automatically adjusts engine governor setting according to load requirement.Determining Cause Of Shutdown
If the engine has been shutdown by a safety device, do not start the engine and place it into service without having the cause of the shutdown investigated and corrected.
Low Oil Pressure Checks
If the low oil pressure shutoff control has stopped the engine, make the following checks: 1. Check the water temperature gauge. Determine if the engine was overheated. Check for external water leaks.
Beware of steam or scalding water. Do not attempt to loosen the radiator cap until the temperature gauge indicates the coolant has sufficiently cooled. Then, loosen the cap slowly.
2. Check the oil level. Oil level must be between the ADD and FULL marks on the side of the dipstick stamped CHECK WITH ENGINE STOPPED.3. If the oil level is below the ADD mark, check for oil spray and/or oil accumulations. If any are found, have the necessary repairs made. Before starting, add oil to the FULL mark.4. Reset the shutoff control.5. Remove the load and start the engine at its slowest speed. Be prepared to shut the engine down manually.6. Be alert for unusual sounds or noises. If the engine knocks, stop the engine immediately and call your Caterpillar dealer.7. If the engine blows excessive black exhaust or has excessive crankcase blow-by, the engine may need reconditioning. Stop the engine and call your Caterpillar dealer.8. If the engine runs satisfactorily, observe the oil pressure gauge. If satisfactory pressure is not indicated, shut the engine down; call your Caterpillar dealer.9. If proper oil pressure is registered, check to see if the reset knob has moved to the run position. If the knob does not move, stop the engine. Check the shutoff control, the oil line, and the oil pressure gauge. Have necessary repairs made.10. If the oil pressure gauge registers normal oil pressure, if the knob on the shutoff
The cause of the shutdown must be investigated and corrected before starting and operating the engine.
Testing Indicator Lights
Most control panels are equipped with a test switch. By turning the switch ON, all of the indicator lights can be checked for proper operation. Test the indicator lights periodically, replace burned out light bulbs immediately.Alarm Shutoff Switch
A switch may be installed in the alarm circuit for silencing the alarm while the engine is stopped for repairs. Be sure the switch is moved to the closed (ON) position and the warning lights are lit before starting.
Place switch in the closed (ON) position when the engine is started, so the engine will be protected.
Output Shaft Governor Operation
When the load can overspeed the torque converter output shaft, an output shaft governor should be installed. The output shaft governor is a speed limiting device which automatically adjusts engine governor setting according to load requirement.Determining Cause Of Shutdown
If the engine has been shutdown by a safety device, do not start the engine and place it into service without having the cause of the shutdown investigated and corrected.
Low Oil Pressure Checks
If the low oil pressure shutoff control has stopped the engine, make the following checks: 1. Check the water temperature gauge. Determine if the engine was overheated. Check for external water leaks.
Beware of steam or scalding water. Do not attempt to loosen the radiator cap until the temperature gauge indicates the coolant has sufficiently cooled. Then, loosen the cap slowly.
2. Check the oil level. Oil level must be between the ADD and FULL marks on the side of the dipstick stamped CHECK WITH ENGINE STOPPED.3. If the oil level is below the ADD mark, check for oil spray and/or oil accumulations. If any are found, have the necessary repairs made. Before starting, add oil to the FULL mark.4. Reset the shutoff control.5. Remove the load and start the engine at its slowest speed. Be prepared to shut the engine down manually.6. Be alert for unusual sounds or noises. If the engine knocks, stop the engine immediately and call your Caterpillar dealer.7. If the engine blows excessive black exhaust or has excessive crankcase blow-by, the engine may need reconditioning. Stop the engine and call your Caterpillar dealer.8. If the engine runs satisfactorily, observe the oil pressure gauge. If satisfactory pressure is not indicated, shut the engine down; call your Caterpillar dealer.9. If proper oil pressure is registered, check to see if the reset knob has moved to the run position. If the knob does not move, stop the engine. Check the shutoff control, the oil line, and the oil pressure gauge. Have necessary repairs made.10. If the oil pressure gauge registers normal oil pressure, if the knob on the shutoff