106661-5120 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615120

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5120 1066615120

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Service parts 106661-5120 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5320

3. GOVERNOR 105489-1500

4. SUPPLY PUMP 105227-1030

5. AUTOM. ADVANCE MECHANIS 105681-4041

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4500

11. Nozzle and Holder 16600-96501

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE

105015-4090

15. NOZZLE SET

Include in #1:

106661-5120 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5120 1066615120

Zexel num

Bosch num

Firm num

Name

106661-5120

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 11.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 116.1 114.1 118.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 101.5 98.5 104.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 14.6 13.3 15.9

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 200+100

Advance angle deg. 1.6 1.1 2.1

Remarks
Start

Timer adjustment_02

Pump speed r/min 500-150

Advance angle deg. 0 0 0

Timer adjustment_03

Pump speed r/min 925+-30

Advance angle deg. 0 0 0

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Damper spring setting: DL (4)Rack limit using stop lever (5)Excess fuel setting for starting: SXL
----------
RT=1 TH=2mm DL=6.3-0.2mm SXL=11.5+0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=24deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=15deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=13mm
----------
a=8deg+-5deg b=33.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

REM05-08
CAT® Reman
February 2005 APPEARANCE CHANGE TO CAT® REMAN DIFN NOZZLES Announcement The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat Reman DIFN nozzles effective 02/04/05. In order to improve the salvage of DIFN nozzles, Cat Reman will begin using bodies for a third life on select DIFN nozzels. The current process allows for only one use. Effective on 02/04/05 they will begin machining the nozzle bodies to allow for a new tip to be pressed in. These nozzles will have the appearance of having a longer tip and shorter body. See pictures below. This change will not alter fit or performance in any way. Part Numbers Impacted
The table below lists part numbers impacted by this change.
Features and Benefits
Cat Remanufactured fuel nozzles offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured fuel nozzles. Cat Remanufactured fuel nozzles provide immediate, off-the-shelf availability at a fraction of the new price.
Features Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Caterpillar® parts distribution system
Customer access regardless of location
Backed by Cat warranty
Consistent support
Core Acceptance Core Acceptance Criteria for Caterpillar Remanufactured fuel nozzles is simple, visual, and requires no special tools. Consult your Core Acceptance Guide for complete details. Warranty Please consult the appropriate warranty statement for your area. Core Management Please refer to the Caterpillar core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail. For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD00390, go to the Reman Dealer website https://reman.cat.com. If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0505 CATERPILLAR® ?2005 Caterpillar