Information injection-pump assembly
ZEXEL
106861-2190
1068612190
Rating:
Service parts 106861-2190 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME066565
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106861-2190
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106861-2190
1068612190
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
1-2-7-3-
4-5-6-8
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
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
140
135.8
144.2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.5
16
21
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.
140
139
141
Basic
*
Fixing the lever
*
Boost pressure
kPa
49.3
49.3
Boost pressure
mmHg
370
370
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11.4)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
132.6
145.4
Difference in delivery
mm3/st.
12.8
12.8
12.8
Fixing the lever
*
Boost pressure
kPa
49.3
49.3
Boost pressure
mmHg
370
370
Injection quantity adjustment_05
Adjusting point
D
Rack position
11.3
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
130
126.3
133.7
Fixing the lever
*
Boost pressure
kPa
17.3
17.3
17.3
Boost pressure
mmHg
130
130
130
Injection quantity adjustment_06
Adjusting point
E
Rack position
-
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
120
100
140
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
9.9
Boost pressure
kPa
2
2
2
Boost pressure
mmHg
15
15
15
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
11.3
Boost pressure
kPa
17.3
16
18.6
Boost pressure
mmHg
130
120
140
Boost compensator adjustment_03
Pump speed
r/min
400
400
400
Rack position
(12.5)
Boost pressure
kPa
35.3
35.3
35.3
Boost pressure
mmHg
265
265
265
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Damper spring setting: DL
(4)Boost compensator stroke: BCL
----------
RT=1 TH=1.9mm DL=5.8-0.2mm BCL=1.5+-0.1mm
----------
----------
RT=1 TH=1.9mm DL=5.8-0.2mm BCL=1.5+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=18deg+-5deg
----------
----------
a=18deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=33deg+-3deg
----------
----------
a=10deg+-5deg b=33deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Fix using the stopper bolt.
(3)Rack position bb
(4)Free (at shipping)
----------
aa=4.7-0.5mm bb=15.3mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)
----------
aa=4.7-0.5mm bb=15.3mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)
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=325+-5r/min Ra=6.7mm
----------
----------
N1=325+-5r/min Ra=6.7mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
PARTS NEEDED
Qty
Part Number Description
1 4716029 MTG GP-INJECTOR (After Failure Only)
1 5548955 DEF SOFTWARE
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
New DEF System software is available that reduces the risk of an internal DEF injector leak by improved temperature management. Please update the DEF system software at the next opportunity.
Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training. Before beginning ANY work on the DEF system, refer to Operations and Maintenance Manual, "General Hazard" for safety information.
Before Failure:
Check that the engine software is the latest version before updating the DEF pump software.
If the engine software is not the latest version, update the Engine Software first.
If needed, update the engine software with the latest available in SIS WEB.
Flash the DEF Pump ECM with the software listed in the Parts Needed or latest available in SIS Web.
After Failure:
Ensure the appropriate steps have been followed when diagnosing a DEF injector failure. Refer to UENR0662.
If it is determined that replacement of DEF injector is required, refer to Disassembly and Assembly Manual - Diesel Fluid Injector - Remove and install.
After the DEF injector has been replaced, perform the DEF system software update as detailed in the "Before Failure" section above.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job
An additional 1.5 hours is allowed for After failure.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.