101495-3350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953350

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101495-3350 1014953350

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Service parts 101495-3350 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8900

3. GOVERNOR 105400-8400

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4710

11. Nozzle and Holder 6202-13-3300

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE

105017-0630

15. NOZZLE SET

Include in #1:

101495-3330 as _

101495-3332

101495-3350 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101495-3350 1014953350

Zexel num

Bosch num

Firm num

Name

101495-3350

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

Overflow valve 131424-7420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-4-3

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 73.5 72.5 74.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 10.5 9.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 12.5+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 65 85

Fixing the lever *

Rack limit *

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)The torque control spring does not operate. (4)RACK LIMIT: RAL
----------
K=14 RAL=12.5+0.2mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.5mm
----------
a=5deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)-
----------

----------
a=58deg+-3deg b=2deg+-30min

Information:

Introduction
This Special Instruction covers the removal procedure for DEF connectors on the models and applications listed above.Safety Section
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Personal injury or death can result from improperly checking for a leak.Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.
Illustration 1 g00104545Prevent the machine from movement. Park the machine on a level surface.Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.Removal Procedure for Single Clip Connectors
Illustration 2 g03468077
(1) Line
(2) Retaining Clip
Clean the area around the connector with compressed air. Be sure to remove any dirt or debris before continuing with this procedure.
Press down on the line (1).
Press IN on the retaining clip (2).
Gently pull straight up on the line.Note: Do not pull out the clip, damage will occur to the retaining clip.Note: Do not pull off the line without the clip being fully depressed, damage will occur to the retaining clip.Removal Procedure for Dual Clip Connectors
Illustration 3 g03468506
(1) Line
(2) Retaining Clips
Clean the area around the connector with compressed air. Be sure to remove any dirt or debris before continuing with this procedure.
Press down on the line (1).
Press IN on the retaining clips (2).
Gently pull straight up on the line.Note: Do not pull out the clip, damage will occur to the retaining clip.Note: Do not pull off the line without the clip being fully depressed, damage will occur to the retaining clip.