106673-7880 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737880

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7880 1066737880

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Cross reference number

ZEXEL 106673-7880 1066737880

Zexel num

Bosch num

Firm num

Name

106673-7880

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 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131425-0220

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.9 3.85 3.95

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 650 650 650

Each cylinder's injection qty mm3/st. 153.5 149.7 157.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8.6+-0.5

Pump speed r/min 360 360 360

Each cylinder's injection qty mm3/st. 15.8 13.4 18.2

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 650 650 650

Average injection quantity mm3/st. 153.5 152.5 154.5

Basic *

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 151.5 147.5 155.5

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_05

Adjusting point D

Rack position R3-1.4

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 90 86 94

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point G

Rack position (R1-2.35 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 106 100 112

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R3-1.4

Boost pressure kPa 5.3 4.6 6

Boost pressure mmHg 40 35 45

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R3(R1-1. 3)

Boost pressure kPa 12 12 12

Boost pressure mmHg 90 90 90

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=AD44 BCL=1.4+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H' (3)Viewed from feed pump side.
----------
aa=45mm
----------
a=30deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.) (2)Normal engine position (Rack position corresponding to cc) (3)Use the hole above R = dd
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=33.5mm
----------
a=41deg+-5deg b=25.5deg+-5deg c=(31deg)+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=8.1+-0.1mm
----------

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=8deg
----------
a=(2deg)

Information:

14May2018
U-275
A-204
D-241
O-246
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 224-4536 CHANGE 06 INJECTION ACTUATION PRESSURE SENSORS FROM DEALER PARTS STOCK
7750 PI70708
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
31Aug2018
PROBLEM
224-4536 change 06 Injector Actuation Pressure Sensor may fail if placed into service.
ACTION REQUIRED
Remove 224-4536 change 06 Injector Actuation Pressure Sensors from dealer parts stock. Image 1 shows a picture of the sensor to remove from the shelves.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.