106673-2300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066732300

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-2300 1066732300

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Service parts 106673-2300 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106060-5140

3. GOVERNOR 105408-0590

4. SUPPLY PUMP 105207-1210

5. AUTOM. ADVANCE MECHANIS 105636-1820

6. COUPLING PLATE 105662-0710

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6211

11. Nozzle and Holder ME059621

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105030-5010

14. NOZZLE

105015-5330

15. NOZZLE SET

Include in #1:

106673-2300 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-2300 1066732300

Zexel num

Bosch num

Firm num

Name

106673-2300

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 131424-4620

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 4.8 4.75 4.85

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 A

Rack position 11.7

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 130 127 133

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 5.7+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 15 12.4 17.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 133 113 153

Fixing the lever *

Rack limit *

Injection quantity adjustment_04

Adjusting point D

Rack position 6

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 10.6 5.4 15.8

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 1 0.5 1.5

Remarks
Finish

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)Torque spring does not operate. (4)RACK LIMIT (5)No set force (6)Main spring setting (7)Set idle sub-spring (8)Set at delivery (9)Rack difference between N = N1 and N = N2
----------
K=7 N1=1150r/min N2=600r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At delivery (3)Pump speed = aa (4)Pump speed = bb
----------
aa=1105r/min bb=955r/min
----------
a=31deg+-5deg b=(2deg) c=7deg+-5deg d=5deg+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(7deg)

Information:

Caterpillar Reference Material
The following literature can be obtained through any Caterpillar dealer.Oil
SEBD0640, Oil and Your EnginePEDP7122, Question & Answer BookletPEDP1129, Listen To Your OilPEHP6001, How to Take a Good Oil SampleSEBU6251, Lubricant RecommendationsPEHP5026, Product Data Sheet for Cat Diesel Engine Oil (DEO) (CG4/CF-4) (North America & Selected International)PEHP1026, Product Data Sheet for Cat Diesel Engine Oil (CF-4)(International Only)PEHP1027, Product Data Sheet for Cat Diesel Engine Oil (CD)PEHP0002, Product Data Sheet for Cat Molybdenum Grease (MPGM)PEHP0003, Product Data Sheet for Cat Lithium Grease (MPGL)PEHP0017, Product Data Sheet for Cat Special Purpose Grease (SPG)PEWP9733, Cat Fluids SelectorPEDP7105, Scheduled Oil SamplingPECP4025, One Safe SourceFuel
SEBD0717, Diesel Fuels and Your EngineCoolant
SEBD0518, Know Your Cooling SystemSEBD0970, Coolant and Your EnginePEHP4036, Data Sheet-Caterpillar CoolantPEHP5033, S O S Coolant AnalysisPECP4025, One Safe SourceMiscellaneous
SEBF8029, Index to Guidelines for Reusable Parts and Salvage OperationsSEBF8062, Guideline for Reusable Parts - Cleaning and Inspection of Air FiltersSEHS9031, Storage Procedure for Caterpillar ProductsSENR5226, Service Manual (EMCP)SEBU6150, SR4 Generators and Control Panels Operation and Maintenance ManualSENR2380, Service Manual (4XB, 7JB, 64Z, 83Z & 10E300-up)SENR2793, Service Manual (85Z, 2AJ & 2TM)SEBP1805, Parts Manual (2AJ)SEBP2273, Parts Manual (2TM)SEBP1451, Parts Manual (7JB)SEBP1452, Parts Manual (4XB)SEBP1406, Parts Manual (85Z)SEBP1411, Parts Manual (83Z)SEBP1435, Parts Manual (64Z)SEBP1400, Parts Manual (10E300-up)SEHS7654, Alignment-General InstructionsSEHS9124, Cleaning and Drying of Caterpillar Electric Set GeneratorsLEBH9324, Agricultural and Material Handling Application and Installation GuideSEHS7292, Use of 5P4150 Nozzle Testing GroupSEHS8622, Using the FT1984 Air-To-Air Aftercooler Leak Test GroupSEHS7795, Use of Pump & Governor Tool GroupSEHS8024, Governor Adjusting Tool GroupSEHS8094, Use of Nozzle Puller GroupAdditional Reference Material
Society of Automotive Engineers (SAE) Specs can be found in your SAE handbook or can be obtained from your local library, college or technological society.* SAE handbooks can be obtained directly from:SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
Engine Manufacturers Association (EMA) information for lube oil selection can be obtained from your local library, college or technological society, or contact:Engine Manufacturers Association
Lubricating Oils Data Book
401 N. Michigan Ave. Ste. 2400
Chicago, IL 60611
(312) 644-6610 ext. 3626
American Society for Testing and Materials (ASTM) specifications can normally be obtained from your local technological siciety, library or college, or contact:American Society for Testing and Materials
1916 Race Street
Philadelphia, PA 19103
Emissions Warranty
The engine described in this manual may be certified and covered by an Emissions Warranty. A detailed explanation of the Emissions Warranty, applicable to certified engines, is found in SEBU6981, Emissions Control Warranty Information. The engine is certified if it has a special certification label. A Caterpillar dealer can also inform you if the engine is certified.