106671-8820 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066718820

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-8820 1066718820

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Service parts 106671-8820 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0291

3. GOVERNOR 105488-2230

4. SUPPLY PUMP 105237-4620

5. AUTOM. ADVANCE MECHANIS 105681-5460

6. COUPLING PLATE 105663-0620

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7366

11. Nozzle and Holder 23600-2412E

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/23.5{240}

13. NOZZLE-HOLDER 105030-3482

14. NOZZLE

15. NOZZLE SET 105019-0161

Include in #1:

106671-8820 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-8820 1066718820

Zexel num

Bosch num

Firm num

Name

106671-8820

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 134424-4420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.84 3.9

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 202 200 204

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 173 170 176

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_03

Adjusting point D

Rack position 3.5+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 10.5 7.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 210 205 215

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Rack limit *

Injection quantity adjustment_05

Adjusting point G

Rack position 7.7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 109 103 115

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 115

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position (7.7)

Boost pressure kPa 13.3 13.3 15.3

Boost pressure mmHg 100 100 115

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position 10.5

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Timer adjustment

Pump speed r/min 700--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 650

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 4 3.7 4.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Stop lever setting: R1 (5)RACK LIMIT (6)Boost compensator stroke: BCL (7)Damper spring setting
----------
RT=1 TH=2.1mm R1=(12.1)+0.5mm BCL=(2.8)mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=13deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the rack position at bb before adjusting the governor (3)Set the stopper screw. (After setting, apply red paint.)
----------
aa=36mm bb=(12.1)+0.5mm
----------
a=35deg+-5deg b=39deg+-5deg

Timing setting

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

----------
a=(0deg)

Information:

Introduction
The following Special Instruction must be used to package a DPF for a core return.
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Note: Whenever the filter is replaced the engine ash model must be reset. Refer to the section below for information on how to reset the ash model.Reset the Engine Ash Model
The engine ash model must be reset whenever the filter is cleaned or replaced. Reseting the ash model places the DPF volume back to the "Clean State". The resetting will allow the regeneration of the DPF to function properly.
Use Cat ET to access the configuration parameters. Select "Service" from the top menu then select "Service Procedures" then select "DPF Ash Service" from the menu in the service tool.
Choose the correct replacement type of diesel particulate filter in the menu that appears. The types of replacements for the diesel particulate filter are the following:
"Field cleaned" A DPF that has been cleaned and reapplied.
"New" A new DPF replacement.
"Remanufactured" A remanufactured DPF replacement.
Once the reset is completed, a log of the reset is captured and visible as a new row of information in the "DPF Ash Service" screen. Resetting the engine ash model does not reset the soot level.
Perform a "Manual DPF Regeneration" with Cat® ET to reset the soot levelPackaging Instructions
Note: The replacement DPF will be packaged with a bag and zip-tie that are used to repackage the DPF that has been removed.
Place the DPF being returned in the enclosed bag and seal the bag with the enclosed zip-tie.
Place the enclosed warning label on the outside of the bag.
Place half of the foam insert on the bottom of the original shipping box with the cut out in the insert facing up.
Place the DPF into the box fitting the DPF into the cut out in the insert.
Place the second half of the foam insert on to of the DPF with the cut out in the insert facing down onto the DPF.
Seal the box with packing tape.Note: If the package weighs over 16 kg (35 lb), additional tape or banding might be required.
Label the package for return shipment.