Information injection-pump assembly
ZEXEL
106676-2600
1066762600
Rating:
Cross reference number
ZEXEL
106676-2600
1066762600
Zexel num
Bosch num
Firm num
Name
106676-2600
INJECTION-PUMP ASSEMBLY
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
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
8.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
93
91
95
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
6+-0.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
16
13.4
18.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
9.4++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
185
175
195
Fixing the lever
*
Rack limit
*
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)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference between N = N1 and N = N2
----------
K=12 N1=1000r/min N2=500r/min
----------
----------
K=12 N1=1000r/min N2=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=5deg+-5deg b=21deg+-5deg
----------
----------
a=5deg+-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
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:
ACTION REQUIRED
Refer to the Service Manual if/as necessary.
Inspect the engine for 20R-1282 Fuel Injectors with serial numbers LESS THAN 1240557.
If the engine has 20R-1282 Fuel Injectors with serial numbers LESS THAN 1240557, replace only the 20R-1282 Fuel Injectors with serial numbers LESS THAN 1240557 with 392-0222 Fuel Injectors.
Refer to Image 1 for the part number and serial number locations.
Record the serial number(s) and part number for the injector(s) removed.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-4380 hrs,
0-6 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 1
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
The serial number(s) and part number for the injector(s) removed must be included in the claim story.
1.0 hour will be allowed for inspecting for suspect injectors.
1.0 hour will be allowed for replacing each 20R-1282 Fuel Injector in the engine with a 392-0222 Fuel Injector.
Reasonable travel time and mileage will be allowed.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-4380 hrs,
0-6 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job for Group 2
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
The serial number(s) and part number for the injector(s) removed must be included in the claim story.
2.0 hours will be allowed for inspecting for suspect injectors.
1.0 hour will be allowed for replacing each 20R-1282 Fuel Injector in the engine with a 392-0222 Fuel Injector.
Reasonable travel time and mileage will be allowed.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
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106676-2600
INJECTION-PUMP ASSEMBLY