106676-2100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066762100

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106676-2100 1066762100

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Cross reference number

ZEXEL 106676-2100 1066762100

Zexel num

Bosch num

Firm num

Name

106676-2100

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 -

Rack position 8.5

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 115.5 112.6 118.4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point F

Rack position 5+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 16.5 14 19

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 115.5 114.5 116.5

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 127 120.6 133.4

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_05

Adjusting point C

Rack position 5.7+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 16.5 14 19

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
(check)

Injection quantity adjustment_06

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

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 R2(R1-0. 85)

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(8.5)

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Timer adjustment

Pump speed r/min 400

Remarks
Measure the actual advance angle.

Timer adjustment_02

Pump speed r/min 800

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 2.5 3.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator cancel stroke: BSL (3)Damper spring setting (4)Boost compensator stroke: BCL
----------
BSL=2.2mm BCL=0.85+-0.1mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=22.5deg+-3deg b=28deg+-5deg

Stop lever angle

S:Stop the pump. (1)Normal use set at engine manufacturer. (2)Free (at delivery) (3)Rack position = aa (4)Stopper bolt setting
----------
aa=2.9-0.5mm
----------
a=35deg+-5deg b=(40deg) c=47.5deg+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=325r/min Ra=5.4+-0.1mm
----------

Timing setting

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

----------
a=(7deg)

Information:

Information Release Memo REM03-29
Reman
October 2003 APPEARANCE CHANGE ON REMAN 3126B AND 3126E HEUI? INJECTORS Announcement The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat Reman 3126B and 3126E HEUI Injectors effective 10/01/03. In order to improve appearance and salvage of injector stator covers, Cat Reman will begin using stator cover marking plates on selected 3126 HEUI injectors. Currently, Cat Reman must remove the old part number and codes from the stator cover by grinding. This process can only be done once and often opens porosity in the stator causing scrap or unacceptable appearance. Effective 9/1/03 Cat Reman will begin using a disposable marking plate. See the picture below. The cover and stator are not serviced separately; the picture is for clarity only. This change will not alter fit or performance in any way. Part numbers affected are 0R1050, 0R9348, 0R9349, 0R9350, 10R0781, 10R0782, and 10R1257. Features And Benefits Cat Remanufactured injectors 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 injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price. Features
All critical engineering changes and updates included
Worldwide availability through Caterpillar? parts distribution system
Backed by Cat warranty Benefits
Improved reliability and performance
Customer access regardless of location
Consistent support
Core Acceptance Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Full core credit is issued when the core is complete, fully assembled, and has an acceptable part number. 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 (SELD0039), 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.
PELJ0235 CATERPILLAR?