Information injection-pump assembly
ZEXEL
101491-9590
1014919590
MAZDA
SLB513800
slb513800
Rating:
Service parts 101491-9590 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
SL01 13 640A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-9590
1014919590
MAZDA
SLB513800
slb513800
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 opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
11.21+-0
.02
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
56.8
56.3
57.3
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
-
Rack position
9.6+-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
*
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
A
Rack position
11.21+-0
.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
56.8
56.3
57.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
11.48+-0
.5
Pump speed
r/min
1700
1700
1700
Average injection quantity
mm3/st.
68.9
66.9
70.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
11.32+-0
.5
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
42
40
44
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
16.3+-0.
5
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 lever
*
Timer adjustment
Pump speed
r/min
1350+-25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1700
Advance angle
deg.
3.5
3.2
3.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: R1, speed N1
(3)RACK LIMIT
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the stopper bolt (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:Engine stop
(1)Use the hole at R = aa
(2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(29deg)+-5deg
----------
aa=39mm
----------
a=14deg+-5deg b=(29deg)+-5deg
0000001501 GOV RACK POSITION CONFIRM
Confirm the governor adjustment rack position.
Standard point A
Set the torque cam B.
(C) Confirmation
(D) Remarks
(N): Speed of the pump
(R) Rack position (mm)
----------
----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.21+-0.02mm Rb=11.32+-0.02mm Rc=11.27+-0.1mm Rd=11.48+-0.05mm Re=11.39+-0.05mm Rf=11.46+-0.05mm
----------
----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.21+-0.02mm Rb=11.32+-0.02mm Rc=11.27+-0.1mm Rd=11.48+-0.05mm Re=11.39+-0.05mm Rf=11.46+-0.05mm
0000001601 LEVER
CL:Center line of camshaft
ST:Stop adjuster screw
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
1. Stop lever adjustment outline
(1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position.
(2)Set the speed lever in the full speed position.
(3)At pump speed Na, position the rack at non-injection position Ra.
(4)Set the stop adjusting screw to fix the speed lever in the idling position.
(5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=5.3-0.5mm
----------
----------
Na=1825r/min Nb=325r/min Ra=5.3-0.5mm
----------
0000001701 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=(11.21)mm Rb=(10.8)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=56.8+-0.5cm3/1000st Q2=48.8+-1cm3/1000st
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=(11.21)mm Rb=(10.8)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=56.8+-0.5cm3/1000st Q2=48.8+-1cm3/1000st
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(130deg)
----------
----------
a=(130deg)
Information:
Oiler Feed Adjustment
If necessary, adjust the lubricator to release approximately four drops of fluid per minute into the starting motor air stream. Be sure there is NO fuel supply to the engine. 1. Push on the air start control lever (1) to crank the engine.2. Count the drops of fluid per minute that are released into the air stream. Turn the needle valve knob (3) counterclockwise to increase the flow and clockwise to decrease the flow of fluid into the air stream.Collector Bowl
Some air starters may be equipped with a collector bowl. The bowl collects used oil after the oil has lubricated the vanes. The bowl also collects moisture condensation from the compressed air. When the collector bowl becomes half full, drain the used lubricant. Never fill the lubricator bowl with oil from the collector bowl- use clean lubricant.Air Tank (If Equipped)
For good life of the air starting motor, the air supply must be free of dirt and water. The air starter requires adequate air pressure in order to operate.* Drain water from the air tank (if equipped). Open the drain valve on the bottom of the air tank to drain the condensation and oil carryover.* Check the air supply pressure. The air starting motor requires a minimum of 620 kPa (90 psi) of air pressure to operate properly. The maximum air pressure must not exceed 1550 kPa (225 psi). The normal air pressure will be 758 kPa (110 psi) to 965 kPa (140 psi).Engine Air Cleaner
Check Air Cleaner Service Indicator
Typical air cleaner indicator, mounted on the air cleaner housing. Your engine may be equipped with a different indicator.A service indicator (if equipped) may be mounted on the air cleaner or in a remote location. A colored piston showing in the window indicates the need for servicing the air cleaner. Observe the air cleaner service indicator. Clean or replace the air cleaner element when the yellow diaphragm enters the red zone or the red piston locks in the visible position. If the air cleaner indicator shows red at any time, clean the filter element or install a new air cleaner element.
Never service the air cleaner with the engine running since this will allow dirt to enter the engine.
If your air cleaner element becomes plugged, the air can split the element filter material. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has air filter elements to service this unit. Contact your Caterpillar dealer for the correct filter element. If equipped with a Light Duty air cleaner element, refer to the 50 Hour interval for information.Single Stage Air Cleaner Elements
Remove and Install Air Cleaner Elements
1. Remove the air cleaner cover (1) and element (2).2. Seal the turbocharger air inlet (3) so that debris can not enter the inlet. Use tape, or secure a clean cloth over the opening.3. Clean the inside of the air cleaner cover and body.4. Inspect the replacement element for damage, dirt or debris.5. Remove the seal from the turbocharger inlet.6. Install a clean,
If necessary, adjust the lubricator to release approximately four drops of fluid per minute into the starting motor air stream. Be sure there is NO fuel supply to the engine. 1. Push on the air start control lever (1) to crank the engine.2. Count the drops of fluid per minute that are released into the air stream. Turn the needle valve knob (3) counterclockwise to increase the flow and clockwise to decrease the flow of fluid into the air stream.Collector Bowl
Some air starters may be equipped with a collector bowl. The bowl collects used oil after the oil has lubricated the vanes. The bowl also collects moisture condensation from the compressed air. When the collector bowl becomes half full, drain the used lubricant. Never fill the lubricator bowl with oil from the collector bowl- use clean lubricant.Air Tank (If Equipped)
For good life of the air starting motor, the air supply must be free of dirt and water. The air starter requires adequate air pressure in order to operate.* Drain water from the air tank (if equipped). Open the drain valve on the bottom of the air tank to drain the condensation and oil carryover.* Check the air supply pressure. The air starting motor requires a minimum of 620 kPa (90 psi) of air pressure to operate properly. The maximum air pressure must not exceed 1550 kPa (225 psi). The normal air pressure will be 758 kPa (110 psi) to 965 kPa (140 psi).Engine Air Cleaner
Check Air Cleaner Service Indicator
Typical air cleaner indicator, mounted on the air cleaner housing. Your engine may be equipped with a different indicator.A service indicator (if equipped) may be mounted on the air cleaner or in a remote location. A colored piston showing in the window indicates the need for servicing the air cleaner. Observe the air cleaner service indicator. Clean or replace the air cleaner element when the yellow diaphragm enters the red zone or the red piston locks in the visible position. If the air cleaner indicator shows red at any time, clean the filter element or install a new air cleaner element.
Never service the air cleaner with the engine running since this will allow dirt to enter the engine.
If your air cleaner element becomes plugged, the air can split the element filter material. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has air filter elements to service this unit. Contact your Caterpillar dealer for the correct filter element. If equipped with a Light Duty air cleaner element, refer to the 50 Hour interval for information.Single Stage Air Cleaner Elements
Remove and Install Air Cleaner Elements
1. Remove the air cleaner cover (1) and element (2).2. Seal the turbocharger air inlet (3) so that debris can not enter the inlet. Use tape, or secure a clean cloth over the opening.3. Clean the inside of the air cleaner cover and body.4. Inspect the replacement element for damage, dirt or debris.5. Remove the seal from the turbocharger inlet.6. Install a clean,