106671-4531 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066714531


 

Information injection-pump assembly

ZEXEL 106671-4531 1066714531
106671-4531 INJECTION-PUMP ASSEMBLY
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Service parts 106671-4531 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106060-5500
3. GOVERNOR 105447-0800
4. SUPPLY PUMP 105237-1730
5. AUTOM. ADVANCE MECHANIS 105639-2100
6. COUPLING PLATE 105664-0280
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4390
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 25.5{260}
13. NOZZLE-HOLDER 105031-4560
14. NOZZLE 105015-5120
15. NOZZLE SET

Include in #1:

106671-4531 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-4531 1066714531


Zexel num
Bosch num
Firm num
Name
106671-4531 
 
   
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   131425-0120
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   3.9 3.85 3.95
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   13.7
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   209.3 204.3 214.3
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.1+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   30 27 33
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   C
Rack position   16.4++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   250 240 260
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   450--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   0.5
Remarks
Measure the actual speed.
 
Timer adjustment_03
Pump speed r/min   720
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106671-4531
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
K=23
----------

Speed control lever angle

Test data 106671-4531
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(31deg)+-5deg b=(31deg)+-5deg

Stop lever angle

Test data 106671-4531
N:Pump normal S:Stop the pump. (1)Right front (2)Right rear (3)Normal
----------

----------
a=47deg+-5deg b=33deg+-5deg c=53deg+-5deg d=36deg+-5deg

Timing setting

Test data 106671-4531
(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. Following the directions in this manual will lower operating costs.The time needed for the engine to reach the normal mode of operation is usually less than the time taken for a walk-around-inspection of the engine.After the engine is started and the cold low idle operation is completed, the engine can be operated at rated speed and low power. The engine will reach normal operating temperature faster when operated at rated speed and low power demand than when idled at no load. Typically the engine should be up to operating temperature in a few minutes.Gauges readings should be observed and the data record frequently while the engine is operating. Comparing the data over time will help determine normal readings for each gauge, and help detect abnormal operating developments. Significant changes in the readings should be investigated.Fuel Conservation Practices
The efficiency of your engine can affect the fuel economy. Caterpillar's state-of-the-art design and manufacturing technology provides maximum fuel efficiency in all applications. Follow the recommended operating and maintenance procedures to attain optimum performance for the life of your engine.* Avoid fuel spillage. Fuel expands when warmed, and may overflow from a too-full fuel tank. Inspect fuel lines for leaks, and repair immediately.* Be aware of the heat values of different fuels. Use only recommended fuels.* Avoid unnecessary idling. Shut the engine off rather than idle for long periods of time (unless the temperature is extremely cold).* Observe the air service indicator frequently, and keep the air cleaner elements clean.* Make sure that turbochargers are operating correctly so that the proper air/fuel ratio is maintained. Clean exhaust indicated proper functioning.* Maintain a good electrical system. One bad battery cell will overwork the alternator, consuming excess power and fuel.* Make sure that belts are properly adjusted and in good condition.* Make sure that all air hose connections are tight and do not leak.* Cold engines consume excess fuel. Utilize jacket water and exhaust system heat when possible. Keep radiator fins and water pumps clean and in good repair. Never operate without thermostats. All of these items will help maintain operating temperatures.* Fuel system settings and altitude limits are stamped on the engine Information Plate. If an engine is moved to a higher altitude, settings must be changed by a Caterpillar dealer in order to prevent turbocharger damage and provide maximum engine efficiency. Engines can be operated safely at lower altitudes, but will deliver less horsepower. The fuel settings should be changed by a Caterpillar dealer to obtain the rated horsepower.

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