101681-9491 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016819491

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101681-9491 1016819491

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Cross reference number

ZEXEL 101681-9491 1016819491

Zexel num

Bosch num

Firm num

Name

101681-9491

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 132424-0620

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 2.2 2.15 2.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.1

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 46.3 44.8 47.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.2+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62.5 62.5 72.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 2.7 2 3.4

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 4.4 3.7 5.1

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 6 6 6

Remarks
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=12 N1=1400r/min N2=900r/min
----------

Speed control lever angle

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

----------
a=27deg+-5deg b=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Never use water alone as a coolant. Water alone is corrosive at engine operating temperatures. In addition, water alone does not provide adequate protection against boiling or freezing.
In engine cooling systems that use water alone, Caterpillar recommends the use of Cat SCA. Cat SCA helps to prevent the following conditions from occurring:
Corrosion
Formation of mineral deposits
Cavitation erosion of the cylinder liner
Foaming of the coolantIf Cat SCA is not used, select a fully formulated commercial SCA. The commercial SCA must provide a minimum of 2400 mg/L or 2400 ppm (140 grains/US gal) of nitrites in the final coolant mixture.The quality of the water is an important factor in this type of cooling system. Distilled water or deionized water is recommended for use in cooling systems. If distilled water or deionized water is not available, use water that meets or exceeds the minimum requirements that are listed in the table for recommended water properties in this Special Publication, "General Coolant Information" topic.A cooling system that uses a mixture of SCA and water only needs more SCA. The SCA concentration in a cooling system that uses SCA and water should be 6 to 8 percent by volume.Maintain the Cat SCA in the same way as you would maintain a cooling system that uses heavy-duty coolant/antifreeze. Adjust the maintenance for the amount ofCat SCA additions.Adding the Cat SCA to Water at the Initial Fill
Use the equation that is in this Special Publication, "Conventional Coolant/Antifreeze Cooling System Maintenance" to determine the amount of Cat SCA that is required at the initial fill. This equation is for a mixture of only Cat SCA and water.Adding the Cat SCA to Water for Maintenance
For the recommended service interval, refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule" for your engine.Submit a coolant sample to your Cat dealer. See this Special Publication, "S O S Services Coolant Analysis" topic.Additions of Cat SCA are based on the results of the coolant analysis. The size of the cooling system determines the amount of Cat SCA that is required.Use the equation that is in this Special Publication, "Conventional Coolant/Antifreeze Cooling System Maintenance" to determine the amount of Cat SCA that is required for maintenance, if necessary:Note: Specific engine applications may require maintenance practices to be periodically evaluated in order to maintain properly the engine cooling system.SCA and part numbers are available from your Cat dealer.