Information injection-pump assembly
ZEXEL
106691-4050
1066914050

Rating:
Service parts 106691-4050 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
106691-4050
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106691-4050
1066914050
Zexel num
Bosch num
Firm num
Name
106691-4050
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11
Pump speed
r/min
1150
1150
1150
Each cylinder's injection qty
mm3/st.
163.7
160.7
166.7
Basic
*
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.3+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
11
9.9
12.1
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
C
Rack position
13.7+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
190
190
220
Fixing the lever
*
Remarks
Boost compensatory excess lever at excess.
Boost compensatory excess lever at excess.
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-1
Boost pressure
kPa
6.7
4
9.4
Boost pressure
mmHg
50
30
70
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11)
Boost pressure
kPa
12
12
12
Boost pressure
mmHg
90
90
90
Timer adjustment
Pump speed
r/min
1150++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1150.
Do not advance until starting N = 1150.
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
1
1
1
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)Boost compensator excessive fuel lever at operation: L1
(4)Boost compensator stroke
----------
K=10 L1=(13.7)mm
----------
----------
K=10 L1=(13.7)mm
----------
Speed control lever angle

F:Full speed
I:Idle
S:Stop
----------
----------
a=14deg+-5deg b=33deg+-5deg c=32deg+-3deg
----------
----------
a=14deg+-5deg b=33deg+-5deg c=32deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=20deg+-5deg b=53deg+-5deg
----------
----------
a=20deg+-5deg b=53deg+-5deg
0000001101

N:Normal
B:When boosted
(1)Rack position = aa
(2)Drive side
----------
aa=(13.7)mm
----------
a=(15deg) b=(15deg)
----------
aa=(13.7)mm
----------
a=(15deg) b=(15deg)
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Select "Create" (9).Note: Two labels and a serial number plate will be sent to the nominated dealer address. If two labels are not received, contact Global_Engine_Marking.
Illustration 23 g06047218
Install the new emissions certification film (10), information label (11), and serial number plate on the cylinder block according to the installation instructions received with the labels and plate.Note: Destroy the old emissions certification film and serial number plate.Operation and Maintenance information
There are several specific messages on this machine. The exact location of the messages and the description of the messages are reviewed in this section. Become familiarized with all messages.Make sure that all messages are legible. Clean the messages or replace the messages if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the messages. Loose adhesive will allow the messages to fall.Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Any Cat® dealer can provide new messages.
Illustration 24 g03516278
Location of films
(1) Engine Oil film
(2) Diesel Fuel Requirements filmEngine Oil (1)
This film is located next to the engine oil filler tube on the right side of the machine.
Illustration 25 g02448560Use Cat® DEO-ULS oils, and oils that satisfy "API CJ-4"and/or "ACEA E9", for engines that are equipped with a diesel particulate filter.Diesel Fuel Requirements (2)
This film is located next to the fuel cap at both sides of the machine.
Illustration 26 g03619316Use Ultralow Sulfur Diesel (ULSD) fuel.The Environmental Protection Agency (EPA) defines Ultra-Low Sulfur Diesel (ULSD - S15) as a diesel fuel with a sulfur content not to exceed 15 parts per million (ppm(mg/kg)), or 0.0015 percent by weight. Engines are equipped with exhaust after-treatment systems are designed to run on ULSD only. Use of LSD or fuels higher than 15 ppm (mg/kg) sulfur in these engines will reduce engine efficiency and engine durability. Damage to the emissions control systems and/or shortened service interval will occur. Failures that result form the use of fuels are not Caterpillar factory defects. Therefore the cost of repairs would not be covered by a Caterpillar warranty.In Europe, ultra low sulfur diesel fuel will have a maximum of 0.0010 percent (10 ppm(mg/kg)) sulfur and is typically referred to as “sulfur-free”. This sulfur level is defined in European Standard "EN 590:2004".Lubricant Viscosities - Fluids Recommendations
Engine Oil
Cat® oils have been developed and tested to provide the full performance and life that has been designed and built into Cat® engines.
Illustration 27 g02448560Cat® DEO-ULS or oils that meet the Cat® ECF-3 specification and the API CJ-4 are required for use in the applications listed below. Cat® DEO-ULS and oils meeting Cat® ECF-3 specification and the API CJ-4 and ACEA E9 oil categories have been developed with limited sulfated ash, phosphorus, and sulfur. These chemical limits are designed to maintain
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106691-4050
INJECTION-PUMP ASSEMBLY