Information injection-pump assembly
ZEXEL
106971-5190
1069715190
Rating:
Cross reference number
ZEXEL
106971-5190
1069715190
Zexel num
Bosch num
Firm num
Name
106971-5190
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
105780-8250
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
10-9-4-3
-6-5-8-7
-2-1
Pre-stroke
mm
4.4
4.37
4.43
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 10-9 deg. 45 44.75 45.25
Cal 10-9 deg. 45 44.75 45.25
Difference between angles 2
Cal 10-4 deg. 72 71.75 72.25
Cal 10-4 deg. 72 71.75 72.25
Difference between angles 3
Cal 10-3 deg. 117 116.75 117.25
Cal 10-3 deg. 117 116.75 117.25
Difference between angles 4
Cal 10-6 deg. 144 143.75 144.25
Cal 10-6 deg. 144 143.75 144.25
Difference between angles 5
Cal 10-5 deg. 189 188.75 189.25
Cal 10-5 deg. 189 188.75 189.25
Difference between angles 6
Cal 10-8 deg. 216 215.75 216.25
Cal 10-8 deg. 216 215.75 216.25
Difference between angles 7
Cal 10-7 deg. 261 260.75 261.25
Cal 10-7 deg. 261 260.75 261.25
Difference between angles 8
Cal 10-2 deg. 288 287.75 288.25
Cal 10-2 deg. 288 287.75 288.25
Difference between angles 9
Cal 10-1 deg. 333 332.75 333.25
Cal 10-1 deg. 333 332.75 333.25
Injection quantity adjustment
Rack position
(13.4)
Vist
V
1.84
1.84
1.84
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
128.5
126.5
130.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(8.8)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
370
370
370
Average injection quantity
mm3/st.
16
14
18
Max. variation between cylinders
%
0
-10
10
Test data Ex:
Governor adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N4=800r/min C4=(9deg) t1=1.7--sec. t2=1.7--sec.
----------
N1=400r/min N2=1000++r/min N3=- C1=9+-0.3deg C2=3.5++deg C3=- P1=0kPa(0kgf/cm2) P2=294kPa(3kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
----------
L=1-0.2mm N4=800r/min C4=(9deg) t1=1.7--sec. t2=1.7--sec.
----------
N1=400r/min N2=1000++r/min N3=- C1=9+-0.3deg C2=3.5++deg C3=- P1=0kPa(0kgf/cm2) P2=294kPa(3kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of the coupling's key groove at the start of injection for the No. 10 cylinder.
(3)-
(4)-
----------
----------
a=(90deg)
----------
----------
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.
----------
----------
----------
----------
Information:
If complete injector sets are replacedon 3412E machines:
PART Hours/Age, whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-4000 0-48 mos 100% 7 0 0 0 0
4001-8000 0-48 mos 33.3% 3.5 0 0 50% 3.5
* This is a 7-hour job. Actual hourspermitted up to maximums noted above.PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Caterpillar Inc.Attn: Fergal O?Shea ? PS50424
Service Claims Room
8201 N. University
Peoria, IL 61615 ***** All Other Dealers *****
Handle the parts in accordance with yourWarranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.
Use "Test for Cylinder Cutout" to determine ifindividual injector replacements (using original injector part) are needed.
Use "Test for Leakage from Poppet Valve" to determineif full injector sets (using new injector parts and software change) areappropriate for repair.
Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine well need to be diagnosed by othermethods.
Cut out one bank of cylinders. Note engine rpmand the fuel position on the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
If this is the third injector failure,related to this Service Letter, and to the same engine serial number within120 calendar days, replace all the injectors and software following SpecialInstruction article REHS1385.It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from PoppetValve:
Warm engine out of Cold Mode to normal operatingtemperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
: Hot oil and components can causepersonal injury. Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port
PART Hours/Age, whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-4000 0-48 mos 100% 7 0 0 0 0
4001-8000 0-48 mos 33.3% 3.5 0 0 50% 3.5
* This is a 7-hour job. Actual hourspermitted up to maximums noted above.PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Caterpillar Inc.Attn: Fergal O?Shea ? PS50424
Service Claims Room
8201 N. University
Peoria, IL 61615 ***** All Other Dealers *****
Handle the parts in accordance with yourWarranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.
Use "Test for Cylinder Cutout" to determine ifindividual injector replacements (using original injector part) are needed.
Use "Test for Leakage from Poppet Valve" to determineif full injector sets (using new injector parts and software change) areappropriate for repair.
Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine well need to be diagnosed by othermethods.
Cut out one bank of cylinders. Note engine rpmand the fuel position on the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
If this is the third injector failure,related to this Service Letter, and to the same engine serial number within120 calendar days, replace all the injectors and software following SpecialInstruction article REHS1385.It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from PoppetValve:
Warm engine out of Cold Mode to normal operatingtemperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
: Hot oil and components can causepersonal injury. Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port
Have questions with 106971-5190?
Group cross 106971-5190 ZEXEL
106971-5190
INJECTION-PUMP ASSEMBLY