106662-4021 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066624021

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106662-4021 1066624021

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Service parts 106662-4021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5280

3. GOVERNOR 105407-2470

4. SUPPLY PUMP 105217-1390

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

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:

106662-4021 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106662-4021 1066624021

Zexel num

Bosch num

Firm num

Name

106662-4021

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 3.3 3.25 3.35

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 9.5

Pump speed r/min 900 900 900

Each cylinder's injection qty mm3/st. 143.3 140.8 145.8

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.5+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 19.4 17.9 20.9

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1. (3)Set idle using the main spring. Operate the solenoid and confirm that it returns at rack position R = R1 or less.
----------
K=5 L1=3.8-0.5mm R1=3.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Set the idle stopper bolt
----------
aa=900r/min bb=750r/min
----------
a=(7deg)+-5deg b=(28deg)+-5deg c=(21deg)+-5deg

Information:

Illustration 4 g01787098
Right side view of machine (A) Hood and guard group (B) Lines group (Air) (C) Air cleaner
Illustration 5 g01787413
Front view of machineInstallation Procedure
Diesel Particulate Filter Installation
Illustration 6 g01787733
(2) 331-8935 Brackets (12) 5P-8245 Hard Washer (13) 6V-8149 Nut (14) 8F-6437 Washer (15) 8T-4956 Bolt
Place two new 331-8935 Brackets (2) parallel to each other on top of the hood. Secure the brackets to the hood using four new 8F-6437 Washers (14), four new 5P-8245 Hard Washers (12), four new 6V-8149 Nuts (13) and four new 8T-4956 Bolts (15). Refer to Illustration 6.
Illustration 7 g01787893
(5) 295-3044 Exhaust Support Gp (Lower half) (14) 8F-6437 Washer (15) 8T-4956 Bolt
Install the two lower halves of the new 295-3044 Exhaust Support Gp (5) onto two brackets (2) using four new 8F-6437 Washers (14) and four new 8T-4956 Bolts (15). Refer to Illustration 7.
Illustration 8 g01788694
(1) 331-8928 Diesel Particulate Filter Gp
Place the new 331-8928 Diesel Particulate Filter Gp (1) onto the two lower halves of exhaust support group (5). The approximate weight of the diesel particulate filter group is 43.6 kg (96.1 lb). Refer to Illustration 8.
Install the two upper halves of exhaust support group (5) onto the lower halves of exhaust support group (5). Secure the two halves of the exhaust support group by using four bolts (5a) and four hard washers (5b). Refer to Illustration 8.
Illustration 9 g01788695
(9) 174-5414 Clamp (11) 255-2899 Tail Pipe As
Connect 255-2899 Tail Pipe As (11) to the outlet module tube of the diesel particulate filter group by using 174-5414 Clamp (9). Refer to Illustration 9.
Illustration 10 g01788698
(3) 331-9162 Filter Tube As (7) 241-6170 Plug (8) 8T-6765 Pipe Plug (10) 209-4589 Clamp
Install the new 331-9162 Filter Tube As (3) to the inlet module tube of the diesel particulate filter group. Secure the connection using one new 209-4589 Clamp (10). Refer to Illustration 10.
Install the new 8T-6765 Pipe Plug (8) and 241-6170 Plug (7) into the respective bosses provided on the filter tube assembly. Refer to Illustration 10.
Illustration 11 g01788714
(6) 270-0112 Bellows
Install the new 270-0112 Bellows (6) to filter tube assembly (3). Secure the connection by using one new Clamp (10). Refer to Illustration 11.
Illustration 12 g01788715
Install the new 331-9161 Filter Tube (4) to bellows (6). Secure the connection by using one new clamp (10). Refer to Illustration 12.
Illustration 13 g01788716
Install the other end of filter tube (4) to the air lines group. Secure the connection by using one new clamp (10). Refer to Illustration 13.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)" for information regarding the installation and the operation of the exhaust monitor.The exhaust monitor is a device designed to monitor the Caterpillar DPF system continuously. The exhaust monitor provides critical information to the vehicle