Information injection-pump assembly
ZEXEL
101405-3260
1014053260
Rating:
Service parts 101405-3260 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
4063269
12.
Open Pre:MPa(Kqf/cm2)
22.0{224}
15.
NOZZLE SET
Cross reference number
ZEXEL
101405-3260
1014053260
Zexel num
Bosch num
Firm num
Name
101405-3260
INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE
14BC PE4A,5A, PE
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
Rack position
Point A R=A
Point A R=A
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
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
79
78
80
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
-
Rack position
7.2+-0.5
Pump speed
r/min
420
420
420
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
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
8.55
Boost pressure
kPa
8
8
10.7
Boost pressure
mmHg
60
60
80
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
9.75
Boost pressure
kPa
32
32
32
Boost pressure
mmHg
240
240
240
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)When the hydraulic cylinder is OFF
(4)Boost compensator stroke: BCL
(5)When hydraulic cylinder ON: P1
(6)Rack difference between N = N1 and N = N2
(7)Adjust the secondary timing before adjusting the governor.
----------
K=9 BCL=1.2+-0.1mm P1=(127+-10kPa,{1.3+-0.1kgf/cm2}) N1=1000r/min N2=650r/min
----------
----------
K=9 BCL=1.2+-0.1mm P1=(127+-10kPa,{1.3+-0.1kgf/cm2}) N1=1000r/min N2=650r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=60mm
----------
a=6deg+-5deg b=31deg+-5deg
----------
aa=60mm
----------
a=6deg+-5deg b=31deg+-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
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
After adjusting the boost compensator (A) (B), tighten the bolts to remove the heads.
(1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2 maximum)
----------
T1=2.9~4.9N-m(0.3~0.5kgf-m) T2=2.5N-m(0.25kgf-m)
----------
----------
T1=2.9~4.9N-m(0.3~0.5kgf-m) T2=2.5N-m(0.25kgf-m)
----------
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=11deg bb=0deg
----------
a=54deg54min+-3deg b=5deg30min+-30min
----------
aa=11deg bb=0deg
----------
a=54deg54min+-3deg b=5deg30min+-30min
Information:
For additional torque specifications, not included in this section, refer to Torque Specifications, SENR3130 available from your Caterpillar dealer.Torque for Standard Fasteners
The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.
Torque for Bolts, Nuts and Taperlock Studs
Use these standard torque values for all fasteners unless otherwise specified in this publication or in the Service Manual.Torque for Metric Fasteners
Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury.Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.The material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). The following chart gives general torques for bolts and nuts with Metric Threads of SAE Grade 8.8 or better quality.
Metric hardware must be replaced with metric hardware. Check parts manual for proper replacement.Torques for Bolts, Nuts and Taperlock Studs with Metric Threads
Torque for Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose.
Torque for Constant Torque Hose Clamps
A constant torque hose clamp can be used in place of any standard hose clamp. make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on the type of hose, fitting material and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of the new, constant torque hose clamps. Constant torque hose clamps should be installed as follows:* To allow for maximum expansion, install clamps at 5.7 N m (50 lb in).* To allow for equal expansion and contraction, install clamps at 10.2 N m (90 lb in).* To allow for maximum contraction, install clamps at 14.1 N m (125 lb in).
The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.
Torque for Bolts, Nuts and Taperlock Studs
Use these standard torque values for all fasteners unless otherwise specified in this publication or in the Service Manual.Torque for Metric Fasteners
Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury.Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.The material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). The following chart gives general torques for bolts and nuts with Metric Threads of SAE Grade 8.8 or better quality.
Metric hardware must be replaced with metric hardware. Check parts manual for proper replacement.Torques for Bolts, Nuts and Taperlock Studs with Metric Threads
Torque for Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose.
Torque for Constant Torque Hose Clamps
A constant torque hose clamp can be used in place of any standard hose clamp. make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on the type of hose, fitting material and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of the new, constant torque hose clamps. Constant torque hose clamps should be installed as follows:* To allow for maximum expansion, install clamps at 5.7 N m (50 lb in).* To allow for equal expansion and contraction, install clamps at 10.2 N m (90 lb in).* To allow for maximum contraction, install clamps at 14.1 N m (125 lb in).
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101405-3260
INJECTION-PUMP ASSEMBLY