106671-4610 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066714610

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-4610 1066714610

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Service parts 106671-4610 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5540

3. GOVERNOR 105407-3980

4. SUPPLY PUMP 105237-1890

5. AUTOM. ADVANCE MECHANIS 105636-1840

6. COUPLING PLATE 105664-0400

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:

106671-4610 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-4610 1066714610

Zexel num

Bosch num

Firm num

Name

106671-4610

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 4.1 4.05 4.15

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 12.5

Pump speed r/min 1175 1175 1175

Each cylinder's injection qty mm3/st. 209 202.7 215.3

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 5.5+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 10.4 9.4 11.4

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 13.2+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 188 188 218

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Boost compensatory excess lever at excess.

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10.1

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (12.5)

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Boost compensator stroke
----------
K=5 L1=(13.2)mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=10deg+-5deg b=35deg+-5deg c=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=20deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Drive side
----------
aa=(13.2)mm
----------
a=(15deg) b=(15deg)

Timing setting

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

----------
a=(60deg)

Information:

Commercial Diesel Engine Oils
The performance of commercial diesel engine oils are based on API categories. These API categories are developed to provide commercial lubricants for a wide variety of diesel engines that operate at various conditions.If Caterpillar DEO (multi-grade) is not used, the following commercial oils are recommended.* API CG-4 Preferred* API CF-4 AllowedAPI CG-4 oils are preferred for Caterpillar engines because of the fuel sulfur level. API CG-4 is the only oil category that evaluates oils with engine tests utilizing 0.05 percent sulfur fuel.The following explanations of these API categories can be used to make the proper choice of a commercial oil. CG-4: This is the newest oil category. CG-4 oils were primarily developed for diesel engines that are operating on 0.05 percent sulfur diesel fuel. All of the laboratory engine tests for this category were run with 0.05 percent sulfur diesel fuel. This category also defines oils that have superior soot discrepancy. CG-4 oils will provide improved viscosity control and improved crankcase cleanliness in applications where oil soot is a problem. CG-4 oils will provide improved viscosity control and improved crankcase cleanliness in applications where oil soot is a problem. CG-4 oils should also be used in engines that contain hydraulically actuated fuel injection pumps; these are the first oils to pass industry tests for foam control and viscosity shear loss. CG-4 oils must also pass recently developed tests for metals corrosion, and wear. CG-4 oils can be used in all Caterpillar engines where CF-4 oils are recommended. CF-4 oils service a wide variety of modern diesel engines. This oil classification was developed with 0.40 percent sulfur diesel fuel. The fuel used in the CF-4 tests represents the type of diesel fuels commonly available world wide. CF-4 oils provide improved piston deposit control and improved oil control when compared to the CE category oils. CF-4 oils also provide improved soot dispersancy compared to CD or CF category oils.Some commercial oils meeting these API specifications may require shortened oil change intervals as determined by close monitoring of oil condition and wear metals (Caterpillar S*O*S Oil Analysis Program preferred).Consult with your Caterpillar dealer for the latest oil recommendations or refer to the following Caterpillar Supplements: SEBU6250, SEBU6251, and SEBU6385.
Failure to follow these oil recommendations can cause shortened engine life due to deposits and or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Direct Injection (DI) Diesel Engines
The TBN for a new oil is dependent on the sulfur level of the fuel used. For direct injection engines running distillate diesel fuel, the minimum new oil TBN (by ASTM D 2896) must be 10 times the fuel sulfur level, and the minimum TBN is 5 regardless of sulfur level, see the chart below.TBN vs Fuel Sulfur for Caterpillar DI Diesel Engines
Y=oil TBN shown by ASTM D2896. X=percent of fuel sulfur by weight. New oil TBN (1). Change oil when the used oil TBN limit (2) is reached.In areas where the fuel sulfur exceeds 1.5 percent, choose an