106671-0131 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710131

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-0131 1066710131

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Cross reference number

ZEXEL 106671-0131 1066710131

Zexel num

Bosch num

Firm num

Name

106671-0131

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 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 R2(11.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 153.8 149.8 157.8

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 11.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 161.7 159.7 163.7

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_03

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.1 9.1 11.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position R1(10.7)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 120.6 118.6 122.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position 12.3

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 171.1 166.1 176.1

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(10.7)

Boost pressure kPa 4

Boost pressure mmHg 30

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 12.3

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Rack limit using stop lever
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DL=6.4-0.2mm
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Timer 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.
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L=1-0.2mm N2=800r/min C2=(6.5)deg t1=2--sec. t2=2--sec.
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N1=1250++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=6.5+-0.5deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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----------
a=31deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At center of threaded hole above R = aa
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aa=17mm
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a=22deg+-5deg b=32.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)R = cc (4)Adjust after setting excess fuel lever.
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aa=1+0.5mm bb=12.3mm cc=50mm
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a=32.5deg+-5deg b=19.5deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa
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aa=13mm
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a=(18deg) b=(32deg)

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1= 5+-0.02V V2f=0.3+0.03V V2i=2.2-0.03V
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Timing setting

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

----------
a=(20deg)

Information:

ACTION REQUIRED
See the attached Rework Procedure.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Service Claim Allowances for Inspection
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
0 1 0 0 0 0
Service Claim Allowances for Replacement of the Filter Housing (if required)
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
100% 1 0 0 0 0
Note: This is a 2-hour job if replacement is necessary.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach. (1-Owner Notification)
(2-Rework Procedure)
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
Safety - THE SPIN ON FUEL FILTER BASE NEEDS TO BE INSPECTED
MODELS INVOLVED - CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B DIESEL STANDBY ENGINES
Dear Caterpillar Product Owner:
The spin-on fuel filter base needs to be inspected on the products listed below. The stud height may be incorrect which can cause the spin-on fuel filter to blow off of the filter base and result in a fuel leakage hazard. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated November 23, 2000 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.
Caterpillar Inc.
Identification #(s)
Attached to November 23, 2000 Service Letter
Rework Procedure
Verification of Stud Height
Shut off the fuel supply to the engine.
Before removing the fuel filter, have a container ready to catch the fuel that will drain from the fuel system.
Remove the "Spin On" Fuel Filter. A filter wrench may be required.
Keep the fuel filter as it will be required for re-installation.
Measure the threaded nipple from the flat surface on the bottom of the filter base to the end of the nipple. See Illustration #1
Illustration #1
Check the stud height measurement from step #5 with Table #1
Table #1 - Stud Height Measurement
Acceptable Unacceptable
Stud Height 23.3 mm & up Less than 23.3 mm
If the stud height is falls in the "Unacceptable" Range, the fuel filter base must be replaced. See fuel filter base replacement instructions.
If the stud height is falls in the "Acceptable" range, the fuel filter should be reinstalled.
Return fuel flow to the engine.
Start the engine and check for leaks.
Replacement of 1N3789 Fuel Filter Base
Remove the fuel priming pump or cover from the base.
Loosen the fuel lines flowing into and out of the filter base.
Remove the fuel line adapters and the sensor (or plug) from the filter base before removing the filter base from the engine.
Remove the two mounts bolts, nuts and washers that mount the filter base. The filter base can then be removed.
Install a new 1N3789 Fuel Filter Base. Using the existing bolts, nuts and washers.
Note: The old 1N3789 Fuel Filter Base is not repairable and must be scrapped.
Reinstall the fuel line adapters and the sensor (or plug) with a new 3J1907 (adapters) and 6V5048 (sensor/plug) O-ring seals.
Reinstall the fuel lines.
Re-install the fuel priming pump or cover with new 9Y8589 and 9Y6094