106672-9840 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066729840

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106672-9840 1066729840

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Service parts 106672-9840 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-7760

3. GOVERNOR 105447-0820

4. SUPPLY PUMP 105217-1460

5. AUTOM. ADVANCE MECHANIS

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:

106672-9840 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106672-9840 1066729840

Zexel num

Bosch num

Firm num

Name

106672-9840

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 134424-1420

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 3.85 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 14.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 234 229 239

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 13.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 219 214 224

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 6.6+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 37.5 34.5 40.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Idle sub spring setting: L1.
----------
K=6 RAL=16.1+0.2mm L1=6.6-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=(31deg)+-5deg b=(32deg)+-5deg c=(8deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Right front (2)Right rear
----------

----------
a=47deg+-5deg b=33deg+-5deg c=53deg+-5deg d=36deg+-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=16deg
----------
a=(6deg)

Information:

ACTION REQUIRED
New DEF system software is available that reduces the risk of an internal DEF injector leak by improved temperature management. Please update the DEF system software at the next opportunity.
Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training. Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Before Failure:
Check that the engine software is the latest version before updating the DEF pump software.
If the engine software is not the latest version, update the Engine Software first.
If needed, update the engine software with the latest available in SIS Web.
Flash the DEF Pump ECM with the software listed in the Parts Needed or latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting "ECM Software - Install".
After Failure:
Ensure the appropriate steps have been followed when diagnosing a DEF injector failure. Refer to UENR0662.
If it is determined that replacement of DEF injector is required, refer to Disassembly and Assembly Manual - Diesel Exhaust Fluid Injector - Remove and Install.
After the DEF injector has been replaced, perform the DEF system software update as detailed in the "Before Failure" section above.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job for Group 1
An additional 2 hours are allowed for After failure
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job for Group 2
An additional 2 hours are allowed for After failure
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.