106693-6185 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066936185

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106693-6185 1066936185

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Service parts 106693-6185 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-1451

3. GOVERNOR 105923-0802

4. SUPPLY PUMP 105237-4760

5. AUTOM. ADVANCE MECHANIS 105681-5330

6. COUPLING PLATE 105664-0831

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7872

11. Nozzle and Holder 8-94390-049-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}/22.1{225}

13. NOZZLE-HOLDER 105030-4660

14. NOZZLE 105025-0051

15. NOZZLE SET

Include in #1:

106693-6185 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106693-6185 1066936185

Zexel num

Bosch num

Firm num

Name

106693-6185

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 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-8620

Overflow valve opening pressure kPa 206 172 240

Overflow valve opening pressure kgf/cm2 2.1 1.75 2.45

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.57 3.63

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 11.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108 106 110

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12.5 9.3 15.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108 107 109

Basic *

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 108 104 112

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

Boost compensator adjustment

Pump speed r/min 525 525 525

Rack position R2-1.7

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 525 525 525

Rack position R1-0.2(R 2)

Boost pressure kPa 58.7 58.7 58.7

Boost pressure mmHg 440 440 440

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 3/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1075

Advance angle deg. 1.5 1 2

Load 4/5

Timer adjustment_05

Pump speed r/min 1350

Advance angle deg. 5.5 5 6

Load 4/5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=AC30 BCL=1.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=3deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt at rack position = bb, speed = cc and confirm non-injection.
----------
aa=55mm bb=1.5+-0.3mm cc=0r/min
----------
a=14deg+-5deg b=44deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=7deg
----------
a=(50deg)

Information:

Caterpillar: Confidential Yellow
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PS0456 - US, CANADA, CACO, LTD COFA - REVISED 10/90
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
(Revised October 1990) U-130 A-88 AU-86.1 1100, 1290 PS0456 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0456" as Part Number, "7755" as Group Number, and "96" as Description Code. If this Program is administered on E200B or EL200B Excavators, it is recommended that the June 22, 1990 Service Letter - PS4442 be done at the same time. This Revised Service Letter replaces the June 25, 1990 Service Letter. Changes have been made to add Affected Product. Termination Date
June 30, 1991
Problem
The fuel injector sleeves in the cylinder head of certain IT14B Integrated Toolcarriers; E110B, E120B, E200B, EL200B, 213B, 214B, 224B, E240B, and EL240B Excavators; 446 Backhoe Loaders; CB-434, CP-563, and CS-563 Compactors; AP-1050 Asphalt Pavers; and 3114 and 3116 Industrial and Generator Set Engines are subject to pitting and erosion due to fuel cavitation between the injector and the sleeve. The sleeves may pit or crack through, allowing fuel to contaminate the coolant. Coolant contaminated with fuel may also damage the radiator and coolant hoses.
Affected Product
Model Identification Number IT14B 3NJ1-42 E110B 8MF1-151 E120B 6JF1-212 E200B* 6KF1-439 6KG1-249 EL200B* 7DF1-986 213B 1EJ1-233, 236-245, 247, 248 214B