106661-5570 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615570

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5570 1066615570

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Service parts 106661-5570 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5460

3. GOVERNOR 105487-6850

4. SUPPLY PUMP 105217-1850

5. AUTOM. ADVANCE MECHANIS 105636-1710

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5950

11. Nozzle and Holder 16600-96510

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

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5580

15. NOZZLE SET

Include in #1:

106661-5570 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5570 1066615570

Zexel num

Bosch num

Firm num

Name

106661-5570

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 132424-0620

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 1-4-2-6- 3-5

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Drive 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 9

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 117.5 116.5 118.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 9.5 8.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using the stop lever: R1 (5)Excess fuel setting for starting: SXL (N = N1) (6)Damper spring setting
----------
RT=1 TH=2.3mm R1=10.8+0.2mm SXL9+0.2mm N1=430r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=21deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At center of threaded hole above R = aa
----------
aa=17mm
----------
a=15deg+-5deg b=29deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the hole at R = aa (3)Rack position bb
----------
aa=50mm bb=10.8+0.2mm
----------
a=26deg+-5deg b=28deg+-5deg

0000001501 ACS

(A) Set screw 1. Aneroid compensator unit adjustment Screw in (A) to obtain L1. 2. Adjustment following governor installation (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
----------
N1=600r/min L1=0.1~0.5mm
----------
R1=9mm R2=(8)mm P1=89+-2.7kPa(668+-20mmHg) P2=70+-0.7kPa(525+-5mmHg) Q1=117.5+-1cm3/1000st Q2=93.5+-2cm3/1000st

Timing setting

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

----------
a=(30deg)

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Certain F2 series machines installed with Tier II or Tier III engines have reported low power from the engine. After troubleshooting, this low power has been diagnosed as being a faulty fuel injection pump.
Table 1
Required Parts
Part Number Part Name
10R-9707 Fuel Injection Pump Gp
10R-9715 Fuel Injection Pump Gp
20R-4832 Fuel Injection Pump Gp
236-8228 Fuel Injection Pump Gp
237-5213 Fuel Injection Pump Gp
248-2356 Fuel Injection Pump Gp
249-9226 Fuel Injection Pump Gp
266-3712 Fuel Injection Pump Gp
274-4962 Fuel Injection Pump Gp
326-8993 Fuel Injection Pump Gp
326-9147 Fuel Injection Pump Gp
368-5413 Fuel Injection Pump Gp
501-4461 Fuel Priming Pump and Primary Filter Gp Replace failed part with new part for your machine.Solution
Before replacing the fuel injection pump, the following actions can be performed to help ensure that the low-pressure fuel system is in good condition.
There is fuel in the fuel tank
Inspect the fuel filter for excess contamination, if necessary, install a new fuel filter
Check the fuel strainer in the bottom of the fuel tank is not blocked or damaged
Check that the fuel lift pump is delivering fuel to the fuel injection pump.
Check that the fuel tank has been regularly drained of any water contamination, and is clear of any debris that could be restricting the fuel flow. See the Operation and Maintenance Manual for correct maintenance practices.All these issues can cause low fuel pressure problems that could lead to thinking the fuel injection pump is faulty. If the low-pressure fuel system is working correctly, then inspect the fuel injection pump for water damage. Refer to special instruction REHS3767. If the fuel injection pump contains rust, then the root cause of the problem is water in the fuel supply.If necessary, a replacement fuel injection pump may be obtained. Refer to disassembly and assembly, "Fuel Injection Pump - Install" for the correct procedure to install a replacement fuel injection pump.Ensure that the fuel supply is clean and the fuel tank does not contain any water or contamination before installing a new Fuel Injection Pump. Also, replace the fuel filter. If a failure occurs, report the failure to the product group by completing a CPI Feedback Form at the Service Information Management System (SIMSi). Reference CPI 373959 and TIB , M0082583 in the form. The link to SIMSi can be found on the Caterpillar Service Information System (SIS).Note: For machines equipped with 501-4461 Fuel Priming Pump and Primary Filter Gp which has an extra water separation volume. Itis recommended to remove any aftermarket water separator.