Information injection-pump assembly
ZEXEL
106651-2250
1066512250
Rating:
Service parts 106651-2250 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME056275
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106651-2250
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106651-2250
1066512250
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
1-5-3-6-
2-4
Pre-stroke
mm
5.1
5.05
5.15
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
12.1
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
140
136.5
143.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.6
15.9
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
140
139
141
Basic
*
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.1)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
135
143
Difference in delivery
mm3/st.
8
8
8
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_05
Adjusting point
D
Rack position
11.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
121
117.4
124.6
Fixing the lever
*
Boost pressure
kPa
26
26
26
Boost pressure
mmHg
195
195
195
Injection quantity adjustment_06
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
90
130
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
10.4
Boost pressure
kPa
5.3
5.3
5.3
Boost pressure
mmHg
40
40
40
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.5
Boost pressure
kPa
26
24.7
27.3
Boost pressure
mmHg
195
185
205
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(12.1)
Boost pressure
kPa
38
31.3
44.7
Boost pressure
mmHg
285
235
335
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Boost compensator cancel stroke: BSL
(2)Boost compensator stroke
(3)Damper spring setting: DL
----------
BSL=2mm DL=5.6-0.2mm
----------
----------
BSL=2mm DL=5.6-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=4deg+-5deg
----------
----------
a=4deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=21deg+-5deg b=36deg+-3deg
----------
----------
a=21deg+-5deg b=36deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at shipping)
----------
aa=4.9-0.5mm bb=14mm
----------
a=25.5deg+-5deg b=(35.5deg) c=0deg+7deg-5deg
----------
aa=4.9-0.5mm bb=14mm
----------
a=25.5deg+-5deg b=(35.5deg) c=0deg+7deg-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325+-5r/min Ra=6mm
----------
----------
N1=325+-5r/min Ra=6mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(7deg)
----------
----------
a=(7deg)
Information:
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
For After failure, and additional 9.0 hours are allowed. A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
If the head gasket has failed follow the rework procedure for both head gasket replacement and for fuel injection pump replacement. Check that the fuel pump has not suffered a mechanical failure that has resulted in a head gasket failure, such as mechanical failure of the advance box due to air ingress. Head gasket failure due to mechanical failure of the fuel pump is not covered by this service letter.
If the head gasket has not failed follow the rework procedure for fuel injection pump replacement only.
Head gasket replacement:
Confirm the head gasket has failed through removal of the cylinder head and visual inspection of the gasket. Remove cylinder head ? refer to Disassembly and Assembly, "Cylinder Head - Remove". Confirm head gasket has failed through visual inspection, as per the images shown in Image 1.1.1.
Clean the cylinder head face and the cylinder block face to remove any deposits on the gasket sealing surface using an appropriate cleaner. Do not use abrasive materials to remove the deposits during the cleaning process to ensure that the correct surface flatness is maintained.
Inspect cylinder head for flatness and distortion. Refer to Image 1.1.2 for surface finish. Refer to System Operation Testing and Adjusting, "Cylinder Head ? Inspect" for more information. Resurface the cylinder head if required as per Testing and Adjusting, "Cylinder Head ? Inspect".
Inspect cylinder block for surface finish on the top deck of the cylinder block. Refer to Image 1.1.2 for surface finish. If the cylinder block is within specifications, install a new 258-4946 Cylinder Head Gasket. If the block is not within specification, refer to Reuse And Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks" for more information.
Note: A 369-3705 Cylinder Head Gasket may be required, depending on reuse and salvage guidelines.
Follow Disassembly and Assembly, "Cylinder Head ? Install" with a new gasket as per above information.
Fuel injection pump replacement:
Follow Disassembly and Assembly, "Fuel Injection Pump - Remove - Delphi DP210". Do not reuse the fuel pump. Record removed fuel pump serial number in claim story. The fuel pump serial number is in the format "12345ABC".
Install the new 483-2328 Fuel Pump as per Disassembly and Assembly, "Fuel Injection Pump - Install - Delphi DP210". Record the installed fuel pump serial number in claim story. It is essential to install the fuel injection pump with the correct engine position to achieve the correct fuel injection timing and the