106671-0170 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710170

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-0170 1066710170

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Cross reference number

ZEXEL 106671-0170 1066710170

Zexel num

Bosch num

Firm num

Name

106671-0170

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 132424-0620

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 R2(12.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 185.6 181.6 189.6

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_02

Adjusting point B

Rack position 12.1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 171 169 173

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_03

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.1 9.1 11.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position R1(10.7)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 120.6 118.6 122.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position R2+0.2

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 186.3 176.3 196.3

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(10.7)

Boost pressure kPa 4

Boost pressure mmHg 30

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2+0.2

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Rack limit using stop lever
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DL=6.4-0.2mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N2=800r/min C2=(6.5)deg t1=2--sec. t2=2--sec.
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N1=1250++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=6.5+-0.5deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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----------
a=(31deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At center of threaded hole above R = aa
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aa=17mm
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a=22deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Adjust after setting excess fuel lever. (2)Use the hole at R = aa (3)Rack position bb (4)Rack position = cc
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aa=50mm bb=1+0.5mm cc=R2+0.2mm
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a=20.5deg+-5deg b=33.5deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa
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aa=13mm
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a=(18deg) b=(32deg)

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1= 5+-0.02V V2f=0.3+0.03V V2i=2.2-0.03V
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Timing setting

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

----------
a=(20deg)

Information:

This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50714" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
November 30, 2005PROBLEM
The fuel injectors on certain 3126B HEUI TruckEngines need to be replaced. Some 3126B engines may have excessive oilconsumption as a result of oil leaking past an internal injector O-ring.AFFECTED PRODUCT
Model Identification Number
3126B 7AS1-75774PARTS NEEDED
Qty
Part Number Description
6 0R9348 INJECTOR GP
6 0R9349 INJECTOR GP
6 0R9350 INJECTOR GP
6 1093207 SEAL-O-RING
6 1333715 RING BACKUP
6 1482903 SEAL-O-RING
6 1495240 RING BACKUP
6 1504105 RING BACKUP
6 2373800 SEAL-O-RING If REMAN is not available the followingpart numbers can be used. A total of 6 injectors needed per engine repair.See SIS Web to determine the injector to be used.
Qty
Part Number Description
6 1881320 INJECTOR GP
6 1961401 INJECTOR GP
6 1964229 INJECTOR GP
6 2184109 INJECTOR GPACTION REQUIRED
If oil consumption suddenly increases and exceeds1/2 Gallon of oil per day and if the engine does not show traditional signsof oil consumption such as blowby or smoke, replace all 6 injectors. Refer to D&A RENR1369 for the injectoruninstall/install procedure.SERVICE CLAIM ALLOWANCES
Product smu Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-150,000 miles37-60 mos 70% 3.3 0 0 30% 1.3
150,001-200,000 miles37-60 mos 50% 2.3 0 0 50% 2.3
200,001-250,000 miles37-60 mos 25% 1.2 0 0 75% 3.4
This is a 4.6?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.