106671-9850 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066719850

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-9850 1066719850

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Cross reference number

ZEXEL 106671-9850 1066719850

Zexel num

Bosch num

Firm num

Name

106671-9850
106671-9851

DPICO

INJECTION-PUMP ASSEMBLY
Q * Q

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 131424-4420

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 1-5-3-6- 2-4

Pre-stroke mm 4.4 4.35 4.45

Beginning of injection position
Governor 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 -

Rack position 13.2

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 181 176.5 185.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position R2(5.6)

Pump speed r/min 300 300 300

Each cylinder's injection qty mm3/st. 13 11.3 14.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.2)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 181 180 182

Basic *

Fixing the lever *

Boost pressure kPa 107 107

Boost pressure mmHg 800 800

Injection quantity adjustment_04

Adjusting point B

Rack position R1(13.2)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 173.5 169.5 177.5

Fixing the lever *

Boost pressure kPa 107 107

Boost pressure mmHg 800 800

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 148 128 168

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 R3-3.3

Boost pressure kPa 3.3 3.3 6.6

Boost pressure mmHg 25 25 50

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R3(R1(13 .1))

Boost pressure kPa 93.3 93.3 93.3

Boost pressure mmHg 700 700 700

Timer adjustment

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 0/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0.5

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2.5 2 3

Load 4/4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Deliver with positive torque control spring not operating (4)Boost compensator stroke: BCL (5)Damper spring setting: DL
----------
RT=1 TH=2.7mm BCL=3.3+-0.1mm DL=R2-0.2mm
----------

Speed control lever angle

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

----------
a=17.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=(38.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting
----------
aa=(3.5)-0.5mm
----------
a=38deg+-5deg b=(38deg)+7deg-5deg

Timing setting

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

----------
a=(6deg)

Information:

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.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former parts and listed in Table 1.
Table 1
Qty New Part Number Part Name Former Part Number
2 303-1968 Gasket 303-1968
4 346-0335 Band Clamp 346-0335
4 536-5400(1) Plate N/A
2 549-2046(2) Clean Emissions Module Ar 536-3638
536-3639
(1) The 536-5400 Plates are used to rework the 536-3638 Catalytic Converter Gp (Left-Hand) and the 536-3639 Catalytic Converter Gp (Right-Hand).
(2) The new 549-2046 Clean Emissions Module Ar is universal and can be installed on both sides of the engine.Inspect the 536-3638 Catalytic Converter Gp (Left-Hand) and the 536-3639 Catalytic Converter Gp (Right-Hand) for cracks before replacing the DOCs. If no cracks are present during inspection, the two 536-5400 Plates can be welded to the top of each DOC for support. Refer to special instruction for the complete list of parts and rework instructions.Note: If the 536-3638 Catalytic Converter Gp (Left-Hand) and the 536-3639 Catalytic Converter Gp (Right-Hand) are reworked, install the DOCs back into the original position. The DOCs are not interchangeable.The special instruction is available through the normal literature distribution system. The publication can also be found on the Caterpillar Service Information System (SIS).