Information injection-pump assembly
ZEXEL
106682-9521
1066829521
Rating:
Service parts 106682-9521 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6212-11-3800
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-9521
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-9521
1066829521
Zexel num
Bosch num
Firm num
Name
106682-9521
INJECTION-PUMP ASSEMBLY
SAA12V14
SAA12V14
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131425-1620
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
1-5-3-6-
2-4
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
14.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
455
450
460
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Remarks
Standard point A's rack position same as row R
Standard point A's rack position same as row R
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.2+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
20
18.5
21.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
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
----------
K=16
----------
----------
K=16
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=23deg+-5deg b=17deg+-5deg
----------
----------
a=23deg+-5deg b=17deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)No return spring
----------
aa=0r/min bb=1-0.5mm
----------
a=(73deg) b=43.5deg+-5deg
----------
aa=0r/min bb=1-0.5mm
----------
a=(73deg) b=43.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(30deg)
----------
aa=20deg
----------
a=(30deg)
Information:
Voltage Regulator and Generator
Clean and Inspect
Before working inside the generator, make sure that the starter motor can not be activated by any automatic or manual signal.When the engine-generator is operating, voltages up to 600V are present in these areas near or on the regulator:1. The regulator terminal strip2. The excitation transformer terminal strip (self-excited generator only).Do not short these terminals to ground with any part of the body or any conductive material. Loss of life or injury could result from electrical shock or injury from molten metal.An electrical shock can be received from the regulator capacitor (C1) when the engine-generator is not in operation. To avoid possible injury, discharge the stored charge using an 100 ohm resistor across C1 terminals.
Electronic components in the regulator can be damaged during generator operation if contact is made between the part and ground.
If Moisture is allowed to remain in contact with an electrical winding, some of the moisture will eventually be absorbed. This will lower the resistance of the winding insulation. The insulation used on the windings of Caterpillar generators is moisture resistant, but constant exposure to moisture will gradually lower the insulation's resistance.Dirt can make the problem worse because it can hold the moisture in contact with the insulation. Salt (from sea air) can also make the problem much worse. This is because salt tends to absorb moisture from the air. When the salt and moisture combine, they make a good electrical conductor.Clean the voltage regulator and generator of dirt and debris. Use a brush to loosen accumulations of dirt and a vacuum system for removal. Use of compressed air is not recommended, because of moisture present in the form of condensate.Carbon tracking on insulators can be caused by dirt or loose connections. These carbon paths must be cleaned or the insulators replaced. Failure to correct a carbon tracking problem will eventually result in a short in the electrical circuit.Visually check for loose or broken wires and connections. Check the wires and connections on the regulator assembly. Check that all circuit boards are fully plugged in their sockets. Check all wires and connections in the generator. Make any necessary repairs to the wiring as required. Refer to the "Electric Set Generator Service Manual" for testing and adjusting or disassembly and assembly procedures.Space Heaters
The SR4 generator can operate in high humidity conditions without problems. However, problems can occur when the generator is idle and the surrounding air is warmer than the generator. Moisture can form on the windings and result in poor performance and even result in damage to the windings. Whenever the generator is not in use, insure that the space heaters are in operation.An external source of either 115 or 230 (200 v at 50 Hz) volts A.C. is required to operate the space heaters. Space Heater Connection to External Source H1, H2, H3, H4. Terminal Strip Terminals If 115 VAC source is available, connect
Clean and Inspect
Before working inside the generator, make sure that the starter motor can not be activated by any automatic or manual signal.When the engine-generator is operating, voltages up to 600V are present in these areas near or on the regulator:1. The regulator terminal strip2. The excitation transformer terminal strip (self-excited generator only).Do not short these terminals to ground with any part of the body or any conductive material. Loss of life or injury could result from electrical shock or injury from molten metal.An electrical shock can be received from the regulator capacitor (C1) when the engine-generator is not in operation. To avoid possible injury, discharge the stored charge using an 100 ohm resistor across C1 terminals.
Electronic components in the regulator can be damaged during generator operation if contact is made between the part and ground.
If Moisture is allowed to remain in contact with an electrical winding, some of the moisture will eventually be absorbed. This will lower the resistance of the winding insulation. The insulation used on the windings of Caterpillar generators is moisture resistant, but constant exposure to moisture will gradually lower the insulation's resistance.Dirt can make the problem worse because it can hold the moisture in contact with the insulation. Salt (from sea air) can also make the problem much worse. This is because salt tends to absorb moisture from the air. When the salt and moisture combine, they make a good electrical conductor.Clean the voltage regulator and generator of dirt and debris. Use a brush to loosen accumulations of dirt and a vacuum system for removal. Use of compressed air is not recommended, because of moisture present in the form of condensate.Carbon tracking on insulators can be caused by dirt or loose connections. These carbon paths must be cleaned or the insulators replaced. Failure to correct a carbon tracking problem will eventually result in a short in the electrical circuit.Visually check for loose or broken wires and connections. Check the wires and connections on the regulator assembly. Check that all circuit boards are fully plugged in their sockets. Check all wires and connections in the generator. Make any necessary repairs to the wiring as required. Refer to the "Electric Set Generator Service Manual" for testing and adjusting or disassembly and assembly procedures.Space Heaters
The SR4 generator can operate in high humidity conditions without problems. However, problems can occur when the generator is idle and the surrounding air is warmer than the generator. Moisture can form on the windings and result in poor performance and even result in damage to the windings. Whenever the generator is not in use, insure that the space heaters are in operation.An external source of either 115 or 230 (200 v at 50 Hz) volts A.C. is required to operate the space heaters. Space Heater Connection to External Source H1, H2, H3, H4. Terminal Strip Terminals If 115 VAC source is available, connect
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106682-9521
INJECTION-PUMP ASSEMBLY
SAA12V14
SAA12V14