107691-2351 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912351

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2351 1076912351

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Service parts 107691-2351 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0171

3. GOVERNOR 105933-0341

4. SUPPLY PUMP 105237-6210

5. AUTOM. ADVANCE MECHANIS 105681-5420

6. COUPLING PLATE 105663-0840

7. COUPLING PLATE

8. _ 159600-3821

9. _

10. NOZZLE AND HOLDER ASSY 105110-7360

11. Nozzle and Holder ME075583

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3110

14. NOZZLE

15. NOZZLE SET 105019-0340

Include in #1:

107691-2351 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107691-2351 1076912351

Zexel num

Bosch num

Firm num

Name

107691-2351

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 131424-8420

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 17

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 5.6 5.57 5.63

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 12.5

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 105 103 107

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

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 465 465 465

Average injection quantity mm3/st. 14 12.2 15.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.5)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 105 104 106

Basic *

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.45

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 102.5 98.5 106.5

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position R1-1.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 90.5 86.5 94.5

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1470

Advance angle deg. 3 2.5 3.5

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

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.
----------
T1=AD54
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=38mm
----------
a=32deg+-5deg b=39.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at rack position = bb, speed = cc and confirm non-injection.
----------
aa=30mm bb=1+-0.3mm cc=0r/min
----------
a=35deg+-5deg b=45deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the timer to align with the pointer's groove. (4)Timer (5)Pointer (6)B.T.D.C.: aa (7)Pre-stroke: bb
----------
aa=5deg bb=5.6+-0.03mm
----------
a=(0deg) b=(37deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000002201 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1450r/min Ra=R1(12.5)+1.45mm
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0000002301 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
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0000002401 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=275r/min Ra=8+-0.1mm
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Information:

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.
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4338" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
June 30, 1999Problem
The 7E7202 Button used in the 7E7205 Rocker Arm Assembly may become separated from the rocker arm when a unit injector sticks during engine operation. Damage to the unit injector may result when the engine is operated with the button separated from the rocker arm.
Affected Product
Model & Identification Number
3606 (8RB298, 8RB585, 8RB590, 8RB591)
3608 (6MC246, 6MC255, 6MC310, 6MC311, 6MC313, 6MC332, 6MC333, 6MC380, 6MC410, 6MC411, 6MC415 , 6MC481, 6MC482, 6MC488-490)
3612 (9RC121, 9RC130, 9RC131, 9RC143, 9RC187, 9RC188)
3616 (1PD24, 1PD82-85, 1PD103, 1PD104, 1PD108-110, 1PD112-115, 1PD117, 1PD119-143 , 1PD148, 1PD154, 1PD156-161, 1PD163, 1PD165, 1PD167, 1PD168, 1PD206 , 1PD211-215, 1PD217, 1PD238, 1PD241-244, 1PD251-261, 1PD264, 1PD267-275 )
Parts Needed
1 - 1514881 Button1 - 5P6031 Wire-LockAction Required
See the attached rework procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
The following procedure provides instructions to install the 1514881 Button onto the 1514918 Rocker Insert used in the 7E7205 Rocker Arm Assembly for the 3600 Series Engine. The button requires a 5P6031 Lock Wire to secure it to the insert.
Recommended Tooling
- Standard or inch tip screwdriver- 10 or 12 inch multiple position pliers (Channel Locks)- 12 oz Ball Peen Hammer- (2.4 mm) PunchInstallation Of 1514881 Button
1. Remove the 1267473 Rocker Arm Group from the engine and place on a work bench. Use a standard or inch tip screw driver to remove the previous 7E7202 Button and 5P8119 O-Ring by prying between the button and rocker arm. 2. Be sure no damage has occurred to the oil passage in the insert. If damage has occurred it is necessary to replace the insert. A 1514883 Rocker Arm Assembly should be used which includes the 1514881 Button and 1514882 Locking Wire assembled to the insert. 3. If there is no damage to the insert hold the 1514881 Button on the insert using a pair of 10 or 12 inch multiple position pliers. The button has a 2.6 mm (0.10 inch) hole in the side. Make sure the hole in the side of the button is in a position so the wire can be inserted. Insert the wire into the hole. 4. With one person holding the button squarely on the insert with pliers, another person is to hold the wire firmly. Apply pressure on the wire and use