101495-3421 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953421

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101495-3421 1014953421

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Cross reference number

ZEXEL 101495-3421 1014953421

Zexel num

Bosch num

Firm num

Name

101495-3421

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

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 10.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 63.5 62.5 64.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.4+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

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 CAP: R1 (4)Idle sub spring setting: L1.
----------
K=15 R1=(17.5)mm L1=5.9-0.5mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
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aa=900r/min bb=750r/min
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a=49deg+-5deg b=24deg+-5deg c=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)No return spring
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aa=1-0.5mm bb=0r/min
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a=27.5deg+-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)- (5)-
----------

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

Information:

Introduction
This technical bulletin pertains to balancing the lubrication to the pin joints on the 994F Wheel Loader.Problem
There is a lack of lubrication to the A-pin.Solution
Increase the amount of grease to the A-pin by decreasing the interval of the lube cycle from 15 minutes (factory setting) to 8 minutes. Decrease the cycle time to 8 minutes by using the VIMS keypad.Adjust the injectors at all other pin joints in order to reduce the grease flow. This will prevent having excess grease at the other pin joints.See the table for each injector setting.
Table 1
Pin Joint Location # Injectors Number of Turns Out Lubricant Volume (in3) Lubricant Volume (mL) mL/Hour
0 0.014 0.2294 0.0000
Hitches (2)
Trunnions (4)
Fan Drive/Belt (2) 8 1 0.022 0.3605 21.6309
F (2)
G (2) 4 2 0.030 0.4916 14.7484
E (2)
Steering Cylinders (4) 6 3 0.038 0.6227 28.0219
B (4)
C (2)
D (2)
K (2)
Y (2) 12 4 0.046 0.7538 67.8424
5 0.054 0.8849 0.0000
6 0.062 1.0160 0.0000
7 0.070 1.1471 0.0000
A (4) 4 8 0.078 1.2782 38.3457
Total mL/Hour 170.5893