Information injection-pump assembly
ZEXEL
101801-9020
1018019020
Rating:
Service parts 101801-9020 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
ZEXEL
101801-9020
1018019020
Zexel num
Bosch num
Firm num
Name
101801-9020
DPICO
INJECTION-PUMP ASSEMBLY
8DC9 * Q
8DC9 * Q
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
131424-4420
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.5
4.45
4.55
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
108.5
105
112
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.3+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
18
15.4
20.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
1.6
1.1
2.1
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
4
3.5
4.5
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
6.5
6.5
6.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT not operating.
(3)Torque spring does not operate.
(4)Rack difference between N = N1 and N = N2
(5)At delivery
(6)Idle sub spring setting: L1.
----------
K=15 N1=900r/min N2=450r/min L1=6.3+-0.1mm
----------
----------
K=15 N1=900r/min N2=450r/min L1=6.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)At delivery
(2)When pump speed set at aa
----------
aa=900r/min
----------
a=24deg+-5deg b=32deg+-3deg c=12deg+-5deg d=(2deg) e=6deg+-5deg
----------
aa=900r/min
----------
a=24deg+-5deg b=32deg+-3deg c=12deg+-5deg d=(2deg) e=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=46deg+-5deg
----------
----------
a=19deg+-5deg b=46deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
In the New Systems, Refilled Systems, and converted systemsEvery year: add to it hours: ever year or every 2000 hours, whichever comes first.When referring to the Service Life in table 1, use the interval that occurs first. These coolant change intervals are only achievable with annual S O S Services Level 2 coolant sampling analysis.Refer to the engine Operation and Maintenance Manual for the correct interval for replacement of the cooling system water temperature regulator.Note: For engines that require a maximum of 20% glycol, make sure that the amount of additive in the final mix is appropriate. Example of mixing a 20% glycol solution is given in Table 3.
Table 3
Example of Mixing Up a 20% Glycol Coolant (1)
Total Volume of the Cooling System Add the Following:
ELC Concentrate ELI Concentrate Water
10 Gallons 2 Gallons 0.5 Gallons 7.5 Gallons
(1) Volumes can also be in liters as long as all the volume units are consistentExtended life coolants require the one time maintenance addition of an extender at coolant service mid-life. For commercial coolants, do NOT use an extender with a coolant unless the extender has been approved by the coolant manufacturer for use with the coolant. The coolant manufacturer is responsible to ensure compatibility and acceptable performance. Failure to follow these recommendations can result in shortened cooling system component life.Conventional coolants require the maintenance addition of SCA throughout the expected life. For commercial coolants, do NOT use an SCA unless approved by the coolant supplier for use with the coolant. The coolant manufacturer is responsible to ensure compatibility and acceptable performance."ASTM D6210" require coolants that are properly dosed with SCA and that are in a properly maintained cooling system in normal service to be suitable for use for a maximum of 2 years. The suitability for use requirement is the direct responsibility of the coolant manufacturer and SCA manufacturer. Consult with the coolant and/or SCA manufacturer concerning the suitability of the products for use in a given application.Cat DEAC is fully formulated and does not require a treatment with an SCA at the initial fill.A commercial heavy-duty coolant/antifreeze that meets the "ASTM D6210"specification does not require a treatment with an SCA at the initial fill.Commercial Heavy Duty coolants that meet only "ASTM D4985" specification are not recommended for Caterpillar applications. These coolants may not provide the performance characteristics needed for heavy duty applications. Cat coolants and the coolants detailed in Table 1 and in this Chapter are formulated to offer the required performance in Cat engines. Refer to Table 1 for Cat coolants recommendations.Cat ELC, Cat ELI, Cat DEAC, Cat Extender, and Cat SCA are available in several container sizes. The availability of part numbers will vary by the region. Consult your Cat dealer.In stationary and marine engine applications that do not require protection from boiling or freezing, except as noted in Table 2, Cat ELI in water or SCA and water are acceptable.
Table 3
Example of Mixing Up a 20% Glycol Coolant (1)
Total Volume of the Cooling System Add the Following:
ELC Concentrate ELI Concentrate Water
10 Gallons 2 Gallons 0.5 Gallons 7.5 Gallons
(1) Volumes can also be in liters as long as all the volume units are consistentExtended life coolants require the one time maintenance addition of an extender at coolant service mid-life. For commercial coolants, do NOT use an extender with a coolant unless the extender has been approved by the coolant manufacturer for use with the coolant. The coolant manufacturer is responsible to ensure compatibility and acceptable performance. Failure to follow these recommendations can result in shortened cooling system component life.Conventional coolants require the maintenance addition of SCA throughout the expected life. For commercial coolants, do NOT use an SCA unless approved by the coolant supplier for use with the coolant. The coolant manufacturer is responsible to ensure compatibility and acceptable performance."ASTM D6210" require coolants that are properly dosed with SCA and that are in a properly maintained cooling system in normal service to be suitable for use for a maximum of 2 years. The suitability for use requirement is the direct responsibility of the coolant manufacturer and SCA manufacturer. Consult with the coolant and/or SCA manufacturer concerning the suitability of the products for use in a given application.Cat DEAC is fully formulated and does not require a treatment with an SCA at the initial fill.A commercial heavy-duty coolant/antifreeze that meets the "ASTM D6210"specification does not require a treatment with an SCA at the initial fill.Commercial Heavy Duty coolants that meet only "ASTM D4985" specification are not recommended for Caterpillar applications. These coolants may not provide the performance characteristics needed for heavy duty applications. Cat coolants and the coolants detailed in Table 1 and in this Chapter are formulated to offer the required performance in Cat engines. Refer to Table 1 for Cat coolants recommendations.Cat ELC, Cat ELI, Cat DEAC, Cat Extender, and Cat SCA are available in several container sizes. The availability of part numbers will vary by the region. Consult your Cat dealer.In stationary and marine engine applications that do not require protection from boiling or freezing, except as noted in Table 2, Cat ELI in water or SCA and water are acceptable.
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Hyundai
Dpico
101801-9020
INJECTION-PUMP ASSEMBLY
8DC9
8DC9