101402-3960 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023960

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3960 1014023960

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Buy INJECTION-PUMP ASSEMBLY 101402-3960 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3960 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9340

3. GOVERNOR 105404-5360

4. SUPPLY PUMP

105220-5960

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

Include in #1:

101402-3960 as INJECTION-PUMP ASSEMBLY

108622-3901 as _

Cross reference number

ZEXEL 101402-3960 1014023960

Zexel num

Bosch num

Firm num

Name

101402-3960

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 131424-3420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 11.6

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 92.5 91.5 93.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 45.3 45.3

Boost pressure mmHg 340 340

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.9+-0.5

Pump speed r/min 335 335 335

Average injection quantity mm3/st. 9 8 10

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. 75 75 85

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 750 750 750

Rack position 10.7

Boost pressure kPa 17.3 16 18.6

Boost pressure mmHg 130 120 140

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 12

Boost pressure kPa 32 25.3 38.7

Boost pressure mmHg 240 190 290

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 (When hydraulic cylinder is OFF) (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2 (7)When hydraulic cylinder ON: P1
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K=8 BCL=1.3+-0.1mm N1=1250r/min N2=750r/min P1=((392)kPa,(4)kgf/cm2)
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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----------
a=(18deg)+-5deg b=(27deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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----------
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.
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aa=16deg bb=0deg
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a=54deg54min+-3deg b=8deg+-30min

Information:

Later Governors Any adjustment to the governor must be made only by a person approved by Caterpillar or by a Caterpillar Dealer.(1) Torque for nut ... 12 4 N m (9 3 lb.ft.).(2) 6N8793 Spring: Length under test force ... 19.05 mm (.750 in.)Test force ... 2.00 0.13 N (.45 .03 lb.)Free length after test ... 41.9 mm (1.65 in.)Outside diameter ... 9.40 mm (.370 in.)(3) Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.(4) 9L6449 Spring for the governor: Color code ... one green stripe, one brown stripePut force on spring of ... 22 N (5 lb.)Then add more force to make spring shorter by ... 22.86 mm (.900 in.)Total test force ... 86.6 1.8 N (19.4 .4 lb.)Free length after test ... 56.9 1 mm (2.24 .04 in.)Outside diameter ... 35.23 mm (1.387 in.)
Install Spring Washers As Shown(4) 9L6448 Spring for the governor: Color code ... one green stripe, one yellow stripePut force on spring of ... 22.24 N (4.00 lb.)Then add more force to make spring shorter by: ... 22.86 mm (.900 in.)Total test force ... 73.00 1.50 N (16.60 .30 lb.)Free length after test ... 56.9 0.8 mm (2.24 .03 in.)Outside diameter ... 35.3 mm (1.39 in.)(5) 9M6303 Spring: Length under test force ... 4.57 mm (1.80 in.)Test force ... 45 4 N (10 1 lb.)Free length after test ... 8.74 mm (.344 in.)Outside diameter ... 12.19 mm (.480 in.)(6) Diameter of the outer surface of the cylinder (new) ... 38.100 0.013 mm (1.5000 .0005 in.)Bore in the gear (new) ... 38.151 0.013 mm (1.5020 .0005 in.).(7) Put marks in alignment on pinion-stop and gear before installing dowel.(8) Bore in the bearing (new) ... 22.263 0.038 mm (.8765 .0015 in.)Diameter of the gear at the hub (new) ... 22.187 0.013 mm (.8735 .0005 in.).
Earlier Governors
Governor Plate(9) Distance from the face of the plate to the bearing for the governor drive assembly ... 0.51 0.25 mm (.020 .010 in.).(10) Dowel installation: Angle A must be ... 54 10°Dimension B must be ... 7.9 0.5 mm (.31 .02 in.)(11) Install dowels to get a dimension of ... 5.6 0.5 mm (.22 .02 in.).
Control Shaft Bearings(12) Bore in the governor control shaft bearings (after assembly) ... 15.761 0.038 mm (.6205 .0015 in.) Diameter of the governor control shaft (new) ... 15.720 0.008 mm (.6189 .0003 in.)(13) Distance between the bearings for the governor control shaft ... 60.58 0.13 mm (2.385 .005 in.)(14) Distance from the face of the housing to the end of the bearing for the governor control shaft ... 43.38 0.15 mm (1.708 .006 in.)
Shutoff Shaft Bearings(15) Bore in the shutoff shaft bearing (new) ... 12.713 0.013 mm (.5005 .0005 in.) Diameter of the shutoff shaft (new)