106672-9640 ZEXEL Calibration Data 1066729640

Information Cross number Calibration Data Calibration Data Ex

Information

ZEXEL 106672-9640 1066729640

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Service parts 106672-9640 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5150

3. GOVERNOR 105447-0740

4. SUPPLY PUMP 105237-1790

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0340

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

106672-9640 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106672-9640 1066729640

Zexel num

Bosch num

Firm num

Name

106672-9640

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 2.65 2.6 2.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 14.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 253 250 256

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 4.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 20 18 22

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Idle sub spring setting: L1.
----------
K=17 RAL=15.2+0.2mm L1=5.6-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(13deg)+-5deg b=(37deg)+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(10deg)

Information:

ACTION REQUIRED
Before completing this Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for your machine.
Choose one of the following actions:
Before Failure: If electronic unit fuel injectors have not failed, reflash the engine ECM with the new software. The new software offers enhanced protection to the fuel system if the fuel/water separator is not drained of water when the "Water Separator Full Indicator" is displayed.
After Failure: If electronic unit fuel injectors have failed, replace the injectors and reflash the engine ECM with the new software.
For detailed instructions on removing and installing the injectors, refer to UENR0633, Disassembly and Assembly, "Electronic Unit Injector - Remove" and "Electronic Unit Injector - Install".
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 1
1 hour to update the software. An additional 3 hours is allowed to replace the injectors, after failure.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 2
1 hour to update the software. An additional 3 hours is allowed to replace the injectors, after failure.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.