106673-7920 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737920

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7920 1066737920

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Cross reference number

ZEXEL 106673-7920 1066737920

Zexel num

Bosch num

Firm num

Name

106673-7920

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 10.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 168.5 165.5 171.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_02

Adjusting point B

Rack position 6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8 5.4 10.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 195 175 215

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-1.65

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1-0.25

Boost pressure kPa 20 13.3 26.7

Boost pressure mmHg 150 100 200

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1(10.6)

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Timer adjustment

Pump speed r/min 825--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 775

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 975

Advance angle deg. 1 0.5 1.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke
----------
K=14
----------

Speed control lever angle

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

----------
a=(21deg)+-5deg b=(7deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Stopper bolt setting (3)Set the outer screw where it contacts the inside (seal at delivery) (4)No return spring
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=70deg+-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=13deg
----------
a=(7deg)

Information:

AFFECTED PRODUCT
Model Identification Number
CB13 PWP00100-00112
CB15 M9400100-00109
CB16 HP500100
CB64B C5600100-00119, 121, 123, 125, 127, 129-132, 134-139, 141-142, 145-146, 150, 153-156, 158, 162-163, 165, 167, 173-174, 178-179, 182-191, 194, 196-198, 202-204, 206-207, 209-213, 216-221, 223, 225-232, 235-243, 245-246, 248, 250-253, 256-259, 261-267, 269-271, 273-274, 276-278, 280-282, 284-285, 287-288, 290-291, 294-296, 300-302, 304-306, 308, 310-311, 313-318, 320, 322-328, 335-336, 339-341, 344-347, 349-354, 358-359, 361-366, 368-369, 371-374, 377, 379-380, 382-385, 387-389, 391-393, 395-397, 400, 402-405, 407, 409, 411, 415, 417-418, 421-424, 427-428, 430, 432, 434-436, 439
CB66B B6600100, 102-103, 105, 109-113, 115, 117-118, 121-123, 125, 128, 130-131, 133-134, 136, 139-140, 145, 149, 152-154, 156, 159-169, 172-178, 181-184, 187-188, 190-191, 194-202, 205, 209-210, 213-215, 217-228, 233-234, 237, 241-242, 245, 247-255, 257-260, 264-267, 269-270, 272-274, 276-277, 280-281, 283, 285-288, 291, 293-296, 299-304, 307, 310-312, 314
CB68B C6800100, 103-104, 106-107, 111-113, 115-116, 124-125, 127-128, 130, 132-140, 142-145, 147, 149-151
PARTS NEEDED
Qty
Part Number Description
1 4716029 MTG GP-INJECTOR (After Failure Only)
1 5548956 DEF SOFTWARE
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
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 the 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%
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
An additional 3 hours are allowed for After failure.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.