101491-9780 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919780


 

Information injection-pump assembly

ZEXEL 101491-9780 1014919780
101491-9780 INJECTION-PUMP ASSEMBLY
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Service parts 101491-9780 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-9720
3. GOVERNOR 105400-7230
4. SUPPLY PUMP 105220-5150
5. AUTOM. ADVANCE MECHANIS 105676-0780
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5230
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105048-3680
14. NOZZLE 105017-0700
15. NOZZLE SET

Include in #1:

101491-9780 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-9780 1014919780


Zexel num
Bosch num
Firm num
Name
101491-9780 
 
   
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   131424-6220
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   1-3-4-2
Pre-stroke mm   3.6 3.55 3.65
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   A
Rack position   11
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   37.7 36.7 38.7
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   10.5+-0. 5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   9.6 8.6 10.6
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Timer adjustment
Pump speed r/min   1200++
Advance angle deg.   0 0 0
Remarks
Do not advance until starting N = 1200.
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   3 3 3
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101491-9780
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)The torque control spring does not operate.
----------
K=6
----------

Speed control lever angle

Test data 101491-9780
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101491-9780
N:Pump normal S:Stop the pump.
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

Test data 101491-9780
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)




Information:

Air Shutoff Solenoid (If Equipped)
This optional solenoid is located on top of the engine in the air inlet system. When the solenoid is activated, the solenoid mechanically shuts off inlet air to the engine. The solenoid can only be activated by the overspeed switch or the emergency stop switch.Fuel Shutoff Solenoid
This solenoid is located on the governor or on the fuel injection pump. When the solenoid is activated, the solenoid moves the fuel rack (either directly or through the governor) to the Fuel Off position.Overspeed Shutoffs
Magnetic pickup (1), mounted in the flywheel housing (2).A magnetic pickup mounted in the flywheel housing senses the passage of the flywheel ring gear teeth. Should the engine speed increase above the overspeed setting of the Electronic Speed Switch (118 percent of rated engine speed), the magnetic pickup will sense the overspeed. The overspeed condition activates both the air (if equipped) and fuel shutoff solenoids.The shutoffs must be reset before the engine will restart. A reset button on the Electronic Speed Switch (in the junction box) must be pushed to open the overspeed switch. The air shutoff lever (at the top of the air inlet housing) must be manually reset.If equipped with a Caterpillar Generator Set Control Panel, the devices on the panel must be reset after an overspeed shutoff. Turn the Engine Control Switch to the OFF/RESET position.Oil Pressure Switches
Typical example of oil pressure switches, mounted in the rear of the junction box.An oil pressure switch has wires connected to the electrical system for alarm or shutoff functions. The oil pressure switch senses oil pressure at the bearing oil gallery. If sufficient oil pressure is not achieved after engine starting, or if the engine has been running normally and then loses oil pressure, the fuel shutoff solenoid is energized to shut the engine off. No resetting procedure is required.Engine Step Oil Pressure
This is an adjustable engine speed setting that protects the engine from a failure caused by too little oil pressure for a specified speed range. This option requires two different oil pressure switches. One switch has a high pressure rating- when the engine is running above the speed setting, the engine must maintain oil pressure higher than the switch rating. The other switch has a low pressure rating- an engine running below the speed setting must maintain oil pressure above the low switch rating.In an automatic start/stop system, an automatic reset switch is used. Manually operated systems require the switch to be reset before the engine will start.
If the RESET button does not move to the extended position after the engine starts, the engine will NOT be protected by this particular switch.If the RESET button remains in the reset position, the engine oil pump will not develop normal oil pressure. An inspection should be made to correct the problem.
In order to reset the switch, push the RESET button until the button latches. After the engine starts and develops oil pressure, the button will move to the extended (running) position.
The button must

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