106961-0380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069610380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106961-0380 1069610380

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Buy INJECTION-PUMP ASSEMBLY 106961-0380 zexel genuine, new aftermarket engine parts with delivery

Service parts 106961-0380 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-5240

3. GOVERNOR 105407-3520

4. SUPPLY PUMP 105217-1730

5. AUTOM. ADVANCE MECHANIS 105636-5030

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-4680

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-3360

15. NOZZLE SET

Include in #1:

106961-0380 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-0380 1069610380

Zexel num

Bosch num

Firm num

Name

106961-0380

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 105780-8140

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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 10-9-4-3 -6-5-8-7 -2-1

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 10-9 deg. 45 44.5 45.5

Difference between angles 2
Cal 10-4 deg. 72 71.5 72.5

Difference between angles 3
Cal 10-3 deg. 117 116.5 117.5

Difference between angles 4
Cal 10-6 deg. 144 143.5 144.5

Difference between angles 5
Cal 10-5 deg. 189 188.5 189.5

Difference between angles 6
Cal 10-8 deg. 216 215.5 216.5

Difference between angles 7
Cal 10-7 deg. 261 260.5 261.5

Difference between angles 8
Cal 10-2 deg. 288 287.5 288.5

Difference between angles 9
Cal 10-1 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point A

Rack position 9.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 115 113 117

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 95 93 97

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 14 12 16

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 300+10

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 3 2.5 3.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 4.7 4.2 5.2

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 8 8 8

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1.
----------
K=7 L1=4.8-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=(23deg)+-5deg b=(3deg)+-5deg c=32deg+-3deg d=(6deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=A a2=E r1=750r/min r2=750r/min Q1=115+-2mm3/st Q2=- c1=+-4% c2=+-4% a3=18 a4=15 r3=900r/min r4=750r/min

Information:

25Sep2017
U-495
A-349
D-407
O-412
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING AN O-RING SEAL ON CERTAIN HEUI REMAN FUEL INJECTORS IN DEALER PARTS STOCK
7750 1290 PI70680
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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.
TERMINATION DATE
31Dec2017
PROBLEM
An incorrect O-ring seal may possibly be included with certain HEUI Reman Fuel Injectors. If the incorrect O-ring seal is installed in an engine, it can cause excessive smoke, oil mixed with fuel, and/or misfire.
ACTION REQUIRED
Inspect the following injector part numbers in dealer parts stock:
0R1050
0R9348
0R9349
0R9350
10R0781
10R0782
10R1257
10R1262
10R1306
10R8999
10R9237
10R9238
10R9239
The incorrect O-ring seal will have a larger in inner diameter and will be not as thick as the 148-2903 O-Ring Seal. The incorrect O-ring seal will be loose on the nozzle case when installed on a fuel injector (Image 1).
The O-ring seals are shipped in a injector seal kit that is included with each injector (Image 2).
Using a 148-2903 O-Ring Seal, compare the injector seal kit to identify if there an incorrect seal. If there is an incorrect seal, replace the incorrect seal with a 148-2903 O-Ring Seal (Image 3).
Once inspected, mark the injector's packaging that it was inspected per this program and return the part to dealer parts stock.
Image1
Image2
Image3
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts inspected and reworked in dealer part stock. 5 minutes will be allowed to inspect each injector and 5 minutes will be allowed to replace incorrect O-Ring. One 148-2903 O-ring per reworked injector will be allowed. Include total amount of injectors inspected or reworked. For each injector that was reworked, include injector serial number.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.