Information injection-pump assembly
ZEXEL
101402-3792
1014023792
Rating:
Service parts 101402-3792 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-3792
1014023792
Zexel num
Bosch num
Firm num
Name
101402-3792
INJECTION-PUMP ASSEMBLY
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
131424-3420
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.5
2.45
2.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.5
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
99.5
98.5
100.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
50.7
50.7
Boost pressure
mmHg
380
380
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.4+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder ON
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
85
85
95
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder OFF
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
R1-1
Boost pressure
kPa
18.7
16
21.4
Boost pressure
mmHg
140
120
160
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
R1(10.5)
Boost pressure
kPa
37.3
30.6
44
Boost pressure
mmHg
280
230
330
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Adjust the secondary timing before adjusting the governor.
(4)RACK LIMIT (When hydraulic cylinder is OFF)
(5)Set idle sub-spring
(6)Main spring setting
(7)The torque control spring must does not have a set force.
(8)Boost compensator stroke: BCL
(9)When hydraulic cylinder ON: P1
----------
K=9 BCL=1+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
----------
K=9 BCL=1+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(18deg)+-5deg b=(37deg)+-5deg
----------
----------
a=(18deg)+-5deg b=(37deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa).
(3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery).
(4)B.T.D.C.: aa
(5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut.
(6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft.
(7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
Information:
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
Termination Date
July 31, 1996Problem
0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 need to be removed from Parts Stock.Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 01, 1995 at plant number 068).
Action Required Cont.
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
TEPS/MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 removed from Parts Stock.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".
Termination Date
July 31, 1996Problem
0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 need to be removed from Parts Stock.Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 01, 1995 at plant number 068).
Action Required Cont.
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
TEPS/MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 removed from Parts Stock.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".
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101402-3792
INJECTION-PUMP ASSEMBLY