Information injection-pump assembly
BOSCH
9 400 611 196
9400611196
ZEXEL
106676-2320
1066762320
Rating:
Service parts 106676-2320 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME158263
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
106676-2320
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 196
9400611196
ZEXEL
106676-2320
1066762320
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
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
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
4.8
4.75
4.85
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
A
Rack position
8.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
123
120
126
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.4+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
9.5
6.9
12.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
145
125
165
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-1.25
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R1(8.9)
Boost pressure
kPa
17.3
10.6
24
Boost pressure
mmHg
130
80
180
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
2.5
2
3
Timer adjustment_02
Pump speed
r/min
300
Advance angle
deg.
2.5
2
3
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
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)Boost compensator stroke: BCL
(6)Set idle sub-spring
(7)Main spring setting
----------
K=6 BCL=1.25+-0.1mm
----------
----------
K=6 BCL=1.25+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(1deg)+-5deg b=(21deg)+-5deg
----------
----------
a=(1deg)+-5deg b=(21deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Stopper bolt setting
(3)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=70deg+-5deg
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=70deg+-5deg
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
Timing setting
(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=12deg
----------
a=(6deg)
----------
aa=12deg
----------
a=(6deg)
Information:
Features
Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Cat parts distribution system
Customer access regardless of location
Off-the-shelf availability
Downtime reduced through exchange product
Same-as-new Caterpillar warranty
Consistent support
Coverage Chart
Reman PN
New PN
Part Name
20R1298
3594090
INJECTOR GP - FUEL
20R1299
3494080
INJECTOR GP - FUEL
20R1301
3594020
INJECTOR GP - FUEL
20R1302
3594040
INJECTOR GP - FUEL
20R1303
3594070
INJECTOR GP - FUEL
20R1304
3597434
INJECTOR GP - FUEL
20R1308
3594050
INJECTOR GP - FUEL
20R1302
3594040
INJECTOR GP - FUEL
20R1317
3809889
INJECTOR GP - FUEL
20R1318
3674293
INJECTOR GP - FUEL
20R3247
3920225
INJECTOR GP - FUEL
20R3607
3820709
INJECTOR GP - FUEL
20R3608
3820745
INJECTOR GP – FUEL
20R3815
3689171
PUMP GP – FUEL INJ
20R3816
3689172
PUMP GP – FUEL INJ
20R3817
3689173
PUMP GP – FUEL INJ
Core Acceptance
The following Core Acceptance Criteria are available supporting these products. All the latest Core Acceptance Criteria guidelines can be found on the Reman Dealer Extranet at https://catreman.cat.com/cac
SELD0226 Unit Injectors Electronic
SELD0023 Fuel Pump & Governor Groups
Warranty
Please consult the appropriate warranty statement for your area by going to warranty.cat.com.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also, refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as “Policy and Core Management” -SELD0122; “Core Management Systems and Operations Procedures” -SELD0040; “Reman Core Return Packaging Instructions And Guidelines” -SELD0300; and “Shipping Instructions” SELD0039.
If you have any questions regarding Reman Core Management or Core Management Systems (CMIS2), feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928.
Contact Information:
For assistance with technical questions, call the Reman Technical Hot Line also toll free at (888) 88-REMAN or use our e-mail address--Reman_Help.
Global Dealer Solutions Network Parts Technical Support Team Toll Free -North America: 1-877-228-2420 International: +1-309-266-4421 Electronic Requests: Send via Microsoft Customer Relationship Management (MSCRM). For access and tutorial information: https://gdsn.cat.com/mscrm
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