Information injection-pump assembly
BOSCH
9 400 614 050
9400614050
ZEXEL
101405-3070
1014053070
KOMATSU
3863835
3863835
Rating:
Service parts 101405-3070 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)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 050
9400614050
ZEXEL
101405-3070
1014053070
KOMATSU
3863835
3863835
Zexel num
Bosch num
Firm num
Name
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
9.7
Pump speed
r/min
1100
1100
1100
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
54
54
Boost pressure
mmHg
405
405
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.9+-0.5
Pump speed
r/min
480
480
480
Average injection quantity
mm3/st.
12.5
11.5
13.5
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
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
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
650
650
650
Rack position
R1-0.75
Boost pressure
kPa
23.3
20.6
26
Boost pressure
mmHg
175
155
195
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1(9.7)
Boost pressure
kPa
40.7
40.7
40.7
Boost pressure
mmHg
305
305
305
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)The torque control spring does not operate.
(4)Adjust the secondary timing before adjusting the governor.
(5)RACK LIMIT (When hydraulic cylinder is OFF)
(6)When hydraulic cylinder ON: P1
(7)Boost compensator stroke: BCL
----------
K=15 P1=(392)kPa{(4)kgf/cm2} BCL=0.75+-0.1mm
----------
----------
K=15 P1=(392)kPa{(4)kgf/cm2} BCL=0.75+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Speed = aa (push-button power increase)
(2)-
(3)Speed = bb (active mode)
(4)Use the center hole above R = cc
----------
aa=1260r/min bb=1210r/min cc=80mm
----------
a=21deg+-3deg b=36deg+-5deg c=3deg+-5deg
----------
aa=1260r/min bb=1210r/min cc=80mm
----------
a=21deg+-3deg b=36deg+-5deg c=3deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
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=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
----------
aa=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
Information:
Engine Lifting
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling. To remove the engine, use the two lifting eyes on the engine.Lifting eyes are designed for the arrangement as sold. Alterations to lifting eyes and/or arrangement weight make the lifting devices obsolete.If you make alterations, you are responsible for providing adequate lifting devices.Engine Storage
If the engine is not started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings. Rust can form on the cylinder liner surface, which will increase engine wear and result in shorter engine life.To prevent excessive engine wear:
Be sure all lubrication recommendations mentioned in the Maintenance Management Schedule intervals chart are completed.If freezing temperatures can be expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar permanent-type antifreeze and approved water will give protection below -20°F (-29°C).If it will be impossible to start the engine every week, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.If an engine remains out of service and its use is not immediately planned, special precautions should be taken.Refer to "Storage Procedures For Caterpillar Products," Form SEHS9031 for more detailed information on engine storage.
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling. To remove the engine, use the two lifting eyes on the engine.Lifting eyes are designed for the arrangement as sold. Alterations to lifting eyes and/or arrangement weight make the lifting devices obsolete.If you make alterations, you are responsible for providing adequate lifting devices.Engine Storage
If the engine is not started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings. Rust can form on the cylinder liner surface, which will increase engine wear and result in shorter engine life.To prevent excessive engine wear:
Be sure all lubrication recommendations mentioned in the Maintenance Management Schedule intervals chart are completed.If freezing temperatures can be expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar permanent-type antifreeze and approved water will give protection below -20°F (-29°C).If it will be impossible to start the engine every week, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.If an engine remains out of service and its use is not immediately planned, special precautions should be taken.Refer to "Storage Procedures For Caterpillar Products," Form SEHS9031 for more detailed information on engine storage.