Information injection-pump assembly
ZEXEL
101495-3410
1014953410
Rating:
Cross reference number
ZEXEL
101495-3410
1014953410
Zexel num
Bosch num
Firm num
Name
101495-3410
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
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
1-2-4-3
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 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
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
44.3
43.3
45.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.8+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
8
7
9
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
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
50
45
55
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)Rack difference between N = N1 and N = N2
----------
K=12 N1=1000r/min N2=750r/min
----------
----------
K=12 N1=1000r/min N2=750r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the pin at R = aa
----------
aa=30mm
----------
a=3deg+-5deg b=19deg+-5deg
----------
aa=30mm
----------
a=3deg+-5deg b=19deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb (stamp at delivery)
(2)No return spring
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
----------
----------
a=58deg+-3deg b=2deg+-30min
----------
----------
a=58deg+-3deg b=2deg+-30min
Information:
Specifications
Illustration 42 g03135400
Table 13
Fuel Injection Pump Camshaft
Model Dimension A Dimension B Dimension C Dimension D Dimension E
3064
3066 40.72 0.25 mm (1.603 0.010 inch) 20.003 0.005 mm (0.7875 0.0002 inch) 11.13 0.25 mm (0.438 0.010 inch) 16.955 0.005 mm (0.6675 0.0002 inch) 16.26 0.25 mm (0.640 0.010 inch) Note: All sprayed edges should be rounded with a 0.795 mm (0.0313 inch) radius.Storage Procedures
Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 43.When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 44.Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
Illustration 43 g06278538
Example of protection for a component that is stored for a shorter term
Illustration 44 g06278539
Example of protection for a component that is stored for a longer period
Illustration 42 g03135400
Table 13
Fuel Injection Pump Camshaft
Model Dimension A Dimension B Dimension C Dimension D Dimension E
3064
3066 40.72 0.25 mm (1.603 0.010 inch) 20.003 0.005 mm (0.7875 0.0002 inch) 11.13 0.25 mm (0.438 0.010 inch) 16.955 0.005 mm (0.6675 0.0002 inch) 16.26 0.25 mm (0.640 0.010 inch) Note: All sprayed edges should be rounded with a 0.795 mm (0.0313 inch) radius.Storage Procedures
Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 43.When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 44.Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
Illustration 43 g06278538
Example of protection for a component that is stored for a shorter term
Illustration 44 g06278539
Example of protection for a component that is stored for a longer period
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101495-3410
INJECTION-PUMP ASSEMBLY