Information injection-pump assembly
BOSCH
9 400 613 254
9400613254
ZEXEL
101405-9460
1014059460
Rating:
Service parts 101405-9460 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
9 400 613 254
9400613254
ZEXEL
101405-9460
1014059460
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
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
3.6
3.55
3.65
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
9.1
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
52
51
53
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.2+-0.5
Pump speed
r/min
575
575
575
Average injection quantity
mm3/st.
9
8
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
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
9.8++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
75
85
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)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference from N = N1
----------
K=11 N1=715r/min
----------
----------
K=11 N1=715r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=1deg+-5deg b=16deg+-5deg
----------
----------
a=1deg+-5deg b=16deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=10deg+-5deg b=53deg+-5deg
----------
----------
a=10deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Gauges provide indications of engine performance. Be sure they are in good working order. You can determine what is the "normal" operating range by observing the gauges over a period of time.Noticeable changes in gauge readings indicate potential gauge or engine problems. This also applies to gauge readings that have changed significantly, but are still within specifications. The cause of any sudden or significant change in gauge readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be greatest after starting a cold engine. Oil pressure should read between 240 and 480 kPa (35 and 70 psi) when: the engine is running at rated engine speed with SAE 10W30 oil, and at operating temperature. A lower pressure is normal at low idling speed.
Engine damage can result if the engine is operated with no oil pressure gauge reading. If no pressure is indicated, stop the engine.
Jacket Water Temperature - Indicates engine coolant temperature. It should normally indicate between 77°C (170°F) and 98°C (209°F). Higher temperatures may occur under certain conditions. Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).Check the charging system for malfunction if, during operation, the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding can seriously damage your engine.
Do not exceed "bare engine high idle" rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. The electrically operated fuel level gauge registers only when the START/STOP (ignition key) switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 160 kPa (23 psi) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of service meter units or clock hours the engine has operated.
Engine damage can result if the engine is operated with no oil pressure gauge reading. If no pressure is indicated, stop the engine.
Jacket Water Temperature - Indicates engine coolant temperature. It should normally indicate between 77°C (170°F) and 98°C (209°F). Higher temperatures may occur under certain conditions. Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).Check the charging system for malfunction if, during operation, the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding can seriously damage your engine.
Do not exceed "bare engine high idle" rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. The electrically operated fuel level gauge registers only when the START/STOP (ignition key) switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 160 kPa (23 psi) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of service meter units or clock hours the engine has operated.