106871-5371 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715371

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5371 1068715371

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Service parts 106871-5371 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5730

3. GOVERNOR 105952-1300

4. SUPPLY PUMP 105237-4710

5. AUTOM. ADVANCE MECHANIS 105683-0240

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7680

11. Nozzle and Holder 16600-97118

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.6{230}

13. NOZZLE-HOLDER 105041-4180

14. NOZZLE

15. NOZZLE SET 105019-0950

Include in #1:

106871-5371 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5371 1068715371

Zexel num

Bosch num

Firm num

Name

106871-5371

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 131425-0120

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

RED3 control unit part number 407910-3 960

RED3 rack sensor specifications mm 19

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-5- 4-3-6-2

Pre-stroke mm 4.7 4.67 4.73

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-5 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-3 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25

Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (13.1)

Vist V 1.89 1.89 1.89

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 126.5 124.5 128.5

Max. variation between cylinders % 0 -4 4

Basic *

Injection quantity adjustment_02

Rack position (8.35)

Vist V 2.6 2.5 2.7

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 13 11 15

Max. variation between cylinders % 0 -10 10

Governor adjustment

Pump speed r/min 700

Advance angle deg. 0.3

Governor adjustment_02

Pump speed r/min -

Advance angle deg. 1.5 1.2 1.8

Remarks
Measure the actual speed.

Governor adjustment_03

Pump speed r/min 1000

Remarks
Measure the actual advance angle.

Governor adjustment_04

Pump speed r/min 1080

Advance angle deg. 7 6.7 7.3

Remarks
Finish

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

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a=(90deg)

Stop lever angle

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:

Caterpillar: Confidential Yellow
PRIORITY - NEW SPRINGS NEED TO BE INSTALLED IN THE UNIT INJECTORS ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PI3 396 - MAILED US, CANADA, CACO, COFA, LIMITED BRAZIL, CFEL, COSA
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.
U-75 A-53 AU-49 B-12.2 E-38.1 O-53.1 PRIORITY parts stock 1290 PI3396 COMPLETION DATE Termination Date
October 31, 1989 April 30, 1990
Problem
The springs in the unit injectors on certain 3606, 3608, 3612, and 3616 Engines may fail and cause unscheduled down time. A spring failure may cause damage to a pushrod or rocker arm.
Affected Product
Model Identification Number 3606 8RB1-293, 296, 297, 314-350, 352, 354, 3608 6MC1-242, 248-250, 251, 253-275, 277-280 5PG1-3 3612 9RC14, 15, 18-47, 52, 53, 57, 58 3616 1PD1-28
Parts Needed
Dealers will need to order parts for this Program. ***** Parts Stock ***** 1 - 7E5404 Spring (1 for each 7C7445 or 7C3854 Injector in the customer or