106676-2040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066762040


 

Information injection-pump assembly

ZEXEL 106676-2040 1066762040
106676-2040 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 106676-2040 1066762040


Zexel num
Bosch num
Firm num
Name
106676-2040 
 
   
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   131424-4620
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4.8 4.75 4.85
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   9.5
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   140.5 137.5 143.5
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   5.8+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   8.5 5.9 11.1
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   125 105 145
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1100
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106676-2040
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)The torque control spring must does not have a set force. (5)Main spring setting (6)Set idle sub-spring
----------
K=8
----------

Speed control lever angle

Test data 106676-2040
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(25deg)+-5deg b=(4deg)+-5deg

Stop lever angle

Test data 106676-2040
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Normal
----------
aa=22mm
----------
a=43.5deg+-5deg b=53deg+-5deg

Timing setting

Test data 106676-2040
(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=13deg
----------
a=(7deg)




Information:


REM02-13
Reman
May 2002 RELOCATION OF SERVICE CENTER FOR 3600 FUEL INJECTORS Announcement Caterpillar is pleased to announce the relocation of the 3600 Fuel Injector Service Center from Booneville, MS to Caterpillar?s Fuel Injector Remanufacturing facility located in Nuevo Laredo, Mexico effective June 01, 2002. This Service Center provides a 3600 Fuel Injector ?Repair and Return? service, principally for dealers in North and South America. This move will in no way effect the excellent service Dealers have come to expect from this program. Injectors in transit to the Boonville, MS facility will be redirected to the Nuevo Laredo facility.Program Dealers can continue to send their 3600 injectors, tagged with Caterpillar? form number 00040279-00 directly to the new address listed below. New forms are being printed with a corrected ship to address. In the interim, Dealers should continue to use the old form. The Dealer will continue to be responsible for freight and insurance to and from the Service Center. The Center will, as in the past, service the injectors and return them, along with an individual certificate of conformity, to wherever the dealer requires. A database with key information on each injector will continue be maintained at the Service Center.The injectors will receive an initial inspection within five days of receipt. Normal turnaround time for the repaired injectors will be 20 ? 30 days. However, should the injectors be required urgently, this can be specified as a special instruction on the shipping tag and accommodated with a premium charge. Special return shipping instructions, such as airfreight, should also be communicated on the shipping tag. If not specified, the repaired injectors will be returned via standard surface freight to the dealer?s main office address.Shipping Location
Caterpillar Inc.
C/O Tecmosa/Dicex International
1101 Black Diamond
International Commerce Center
Laredo, TX 78045
Attn: 3600 Injector Service Center
The new Service Center Customer Service telephone number is: 1877-536-5460.
Features And BenefitsThe service provided will be a ?repair and return? service of the customer?s serialized injector, as opposed to a Reman exchange for a customer?s core. The customer will get his own injector back. It will have been completely disassembled with each component inspected, and after re-assembly, 100% tested against new specifications. A technical report will be completed and returned with each injector to help the dealer analyze any fuel system related problems, which if corrected could possibly help extend the life of the injectors.This service does not replace the remanufactured injector program. It complements it as another repair option offered at a price comparable to the competition. The dealer may choose to have the injectors cleaned or repaired. Or, depending on the need, a remanufactured injector can still be purchased. In this case the Service Center will notify the dealer and transfer the core to Reman, establishing a core credit for the dealer. This Service Center will provide one more way to lower the customer?s owning and operating expenses.Price A flat labor charge of $200 US plus any new components replaced will be

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