Information injection-pump assembly
ZEXEL
101402-3940
1014023940
Rating:
Service parts 101402-3940 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
101402-3940
1014023940
Zexel num
Bosch num
Firm num
Name
101402-3940
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
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
76
75
77
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.7+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
13.5
12.5
14.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
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
*
Rack limit
*
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)Adjust the secondary timing before adjusting the governor.
(4)RACK LIMIT
(5)The torque control spring must does not have a set force.
(6)Rack difference between N = N1 and N = N2
(7)Rack difference between N = N3 and N = N4
----------
K=11 N1=1250r/min N2=400r/min N3=1250r/min N4=700r/min
----------
----------
K=11 N1=1250r/min N2=400r/min N3=1250r/min N4=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)-
----------
----------
a=15deg+-5deg b=32deg+-3deg c=32deg+-5deg
----------
----------
a=15deg+-5deg b=32deg+-3deg c=32deg+-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=16.5deg bb=0deg
----------
a=54deg54min+-3deg b=8deg15min+-30min
----------
aa=16.5deg bb=0deg
----------
a=54deg54min+-3deg b=8deg15min+-30min
Information:
December 9, 2005
U-389
A-289
D-306
O-325
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN FUEL INJECTORS FROM DEALERS PARTS STOCK
7750 PI70111
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2006PROBLEM
A machining error can cause the valve body tocrack through the high-pressure line. This crack can result in fuel inthe engine oil.ACTION REQUIRED
All 10R-0957 unit injectors within serial numberrange 848368-850132 should be removed from parts stock. All 10R-0960, 10R-0961,and 10R-0963 within serial number range 188029-188914 should be removedfrom parts stock.SERVICE CLAIM ALLOWANCES
Submit one claim for all 10R0957, 10R0960, 10R0961,and 10R0963 Injectors removed from parts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70111.***** U.S. and Canadian Dealers *****Return all 10R0957, 10R0960, 10R0961, and 10R0963Injectors that are removed from parts stock and a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery PI70111
Service Claims Room
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
U-389
A-289
D-306
O-325
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN FUEL INJECTORS FROM DEALERS PARTS STOCK
7750 PI70111
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2006PROBLEM
A machining error can cause the valve body tocrack through the high-pressure line. This crack can result in fuel inthe engine oil.ACTION REQUIRED
All 10R-0957 unit injectors within serial numberrange 848368-850132 should be removed from parts stock. All 10R-0960, 10R-0961,and 10R-0963 within serial number range 188029-188914 should be removedfrom parts stock.SERVICE CLAIM ALLOWANCES
Submit one claim for all 10R0957, 10R0960, 10R0961,and 10R0963 Injectors removed from parts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70111.***** U.S. and Canadian Dealers *****Return all 10R0957, 10R0960, 10R0961, and 10R0963Injectors that are removed from parts stock and a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery PI70111
Service Claims Room
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
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Komatsu
101402-3940
INJECTION-PUMP ASSEMBLY