106671-9630 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066719630

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-9630 1066719630

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Cross reference number

ZEXEL 106671-9630 1066719630

Zexel num

Bosch num

Firm num

Name

106671-9630

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 131424-1520

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 1-5-3-6- 2-4

Pre-stroke mm 3.8 3.75 3.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.6

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 168 166 170

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 14 12.5 15.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_02

Pump speed r/min 850

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 2.5 3.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Damper spring setting
----------

----------

Speed control lever angle

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

----------
a=(16.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa
----------
aa=50mm
----------
a=21deg+-5deg b=33deg+-3deg

Stop lever angle

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

----------
a=32deg+-5deg b=64deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(150deg)

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
DEF heated lines can get damaged during handling or other failure modes and leak diesel exhaust fluid on Clean Emission Module (CEM) and other components.Solution
Caterpillar is aware of this problem and is recommending the following interim corrective action.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Rework Procedure
Note: This procedure is meant for temporary repair of a DEF line to allow the machine to be safely transported to the repair shop.
Table 1
Required Parts
Part Number Part Name
473-2053 Diesel Exhaust Fluid Lines Gp (5/16th 90 degree adapter)
473-2055 Diesel Exhaust Fluid Lines Gp (5/16th straight adapter)
473-2056 Diesel Exhaust Fluid Lines Gp (3/8th 90 degree adapter)
473-2057 Diesel Exhaust Fluid Lines Gp (38th 90 Straight adapter)
Table 2
Required Tools
Part Number Part Name
1U-7648 Tube Cutter
Illustration 1 g06433660
Cut the connector end on the corrugated section with the cutter.
Illustration 2 g06433665
Cut the two wires with a tie cutter.
Illustration 3 g06433668
Use a knife or sharp blade to cut the outer sheathing off. Ensure not to cut or damage the inner fluid hose.
Illustration 4 g06433669
Install the hose clamp provided first before installing the connector. Use appropriate size (3/8th or 5/16th) and type (90 degree or straight) fitting.
Illustration 5 g06433672
Fasten the clamp until the two jaws are either in contact or about 2 to 3 mm (0.08 to 0.1 inch) apart.