Information injection-pump assembly
ZEXEL
106671-2670
1066712670
Rating:
Cross reference number
ZEXEL
106671-2670
1066712670
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
10
Pump speed
r/min
600
600
600
Each cylinder's injection qty
mm3/st.
156
152.5
159.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
F
Rack position
5+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
156
155
157
Fixing the lever
*
Boost pressure
kPa
70.6
70.6
Boost pressure
mmHg
530
530
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
167.8
164.2
171.4
Difference in delivery
mm3/st.
7.2
7.2
7.2
Fixing the lever
*
Boost pressure
kPa
70.6
70.6
Boost pressure
mmHg
530
530
Injection quantity adjustment_05
Adjusting point
D
Rack position
7.9+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
105
101.8
108.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
C
Rack position
5.7+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
(check)
(check)
Injection quantity adjustment_07
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
100
80
120
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
(7.9)
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
8.9
Boost pressure
kPa
17.3
17.3
17.3
Boost pressure
mmHg
130
130
130
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
9.9
Boost pressure
kPa
53.3
52
54.6
Boost pressure
mmHg
400
390
410
Boost compensator adjustment_04
Pump speed
r/min
600
600
600
Rack position
R1(10)
Boost pressure
kPa
57.3
57.3
57.3
Boost pressure
mmHg
430
430
430
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
2.3
1.8
2.8
Timer adjustment_04
Pump speed
r/min
1050
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Boost compensator cancel stroke: BSL
(3)Boost compensator stroke
----------
DL=4.5-0.2mm BSL=3mm
----------
----------
DL=4.5-0.2mm BSL=3mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=18deg+-5deg
----------
----------
a=18deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=29.5deg+-5deg b=31deg+-3deg
----------
----------
a=29.5deg+-5deg b=31deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at delivery)
----------
aa=4.1-0.5mm bb=13.3mm
----------
a=26deg+-5deg b=(38deg) c=0deg+7deg-5deg
----------
aa=4.1-0.5mm bb=13.3mm
----------
a=26deg+-5deg b=(38deg) c=0deg+7deg-5deg
0000001501 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=325+-5r/min Ra=5.4mm
----------
----------
N1=325+-5r/min Ra=5.4mm
----------
Information:
Altitude Operation
The fuel system settings and altitude limits are stamped on the engine information plate. When an engine is moved to a higher altitude, these settings must be changed by your Caterpillar dealer in order to prevent damaging the turbocharger, and to provide maximum engine efficiency. If the engine is moved to a lower altitude than that which is stamped on the engine information plate, the engine can be operated safely; however, it will deliver less than rated horsepower, and the fuel settings should be changed by your Caterpillar dealer to obtain rated horsepower.Stopping
1. Flywheel clutch operation: Quickly pull the clutch lever to the released position. For electric set operation, see the GENERATOR SET OPERATION instructions. For Woodward Governor operation, see the topic, WOODWARD GOVERNORS, Stopping the Engine. 2. Reduce engine speed to half speed. Run for 5 minutes to cool engine.3. Reduce engine speed to low idle.4. Observe the crankcase oil level while the engine is idling. Maintain the oil level between the ADD and FULL marks on the side of the dipstick stamped, CHECK WITH ENGINE RUNNING. See the LUBRICATION AND MAINTENANCE SECTION.5. Stop the engine. After Stopping Checks And Procedures
1. Fill the fuel tank. See the LUBRICATION AND MAINTENANCE SECTION: Fuel Tank Maintenance.2. Drain the raw water system if below freezing temperatures are expected; see: Draining Raw Water System.3. If below freezing temperatures are expected, allow the engine jacket water expansion tank to cool; then check the coolant for proper antifreeze protection. Add permanent-type antifreeze, if required.4. Repair any leaks, make major adjustments, tighten loose bolts, etc.5. Observe the Service Meter reading. Perform the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART.
SERVICE METER
The fuel system settings and altitude limits are stamped on the engine information plate. When an engine is moved to a higher altitude, these settings must be changed by your Caterpillar dealer in order to prevent damaging the turbocharger, and to provide maximum engine efficiency. If the engine is moved to a lower altitude than that which is stamped on the engine information plate, the engine can be operated safely; however, it will deliver less than rated horsepower, and the fuel settings should be changed by your Caterpillar dealer to obtain rated horsepower.Stopping
1. Flywheel clutch operation: Quickly pull the clutch lever to the released position. For electric set operation, see the GENERATOR SET OPERATION instructions. For Woodward Governor operation, see the topic, WOODWARD GOVERNORS, Stopping the Engine. 2. Reduce engine speed to half speed. Run for 5 minutes to cool engine.3. Reduce engine speed to low idle.4. Observe the crankcase oil level while the engine is idling. Maintain the oil level between the ADD and FULL marks on the side of the dipstick stamped, CHECK WITH ENGINE RUNNING. See the LUBRICATION AND MAINTENANCE SECTION.5. Stop the engine. After Stopping Checks And Procedures
1. Fill the fuel tank. See the LUBRICATION AND MAINTENANCE SECTION: Fuel Tank Maintenance.2. Drain the raw water system if below freezing temperatures are expected; see: Draining Raw Water System.3. If below freezing temperatures are expected, allow the engine jacket water expansion tank to cool; then check the coolant for proper antifreeze protection. Add permanent-type antifreeze, if required.4. Repair any leaks, make major adjustments, tighten loose bolts, etc.5. Observe the Service Meter reading. Perform the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART.
SERVICE METER