106676-2440 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066762440

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106676-2440 1066762440

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Cross reference number

ZEXEL 106676-2440 1066762440

Zexel num

Bosch num

Firm num

Name

106676-2440

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 12

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 131 127.7 134.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 410 410 410

Each cylinder's injection qty mm3/st. 21 17.8 24.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 131 130 132

Basic *

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.15

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 132 128 136

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Injection quantity adjustment_05

Adjusting point D

Rack position (R1-0.65 )

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 129 123 135

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-0.85

Boost pressure kPa 7.3 6 8.6

Boost pressure mmHg 55 45 65

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 05)

Boost pressure kPa 11.3 11.3 11.3

Boost pressure mmHg 85 85 85

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. 2 1.5 2.5

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=AG53 BCL=0.85+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Viewed from feed pump side. (2)Stopper bolt set position 'H'
----------

----------
a=32.5deg+-5deg b=40deg+-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=40deg+-5deg b=25.5deg+-5deg c=(31deg)+-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=10deg
----------
a=(2deg)

Information:

face="Courier New" size=-1>0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 2
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 3*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 3
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 4*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 4
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 5*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 5
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Engine Injector Change:
First identify which level of injector you currently have in your engine and establish which is the latest injector to replace it.
To remove and replace the injectors use the following Disassembly and Assembly Instructions.
C6.6 Caterpillar Industrial Engines: Install and Remove procedure RENR9722
C6.6 Caterpillar Built Machine: Install and Remove procedure KENR6081
Engine Reflash:
To update the flash file follow the procedure below. Refer to TMI or SISWeb for the latest flash file.
Tools Required:
PC or laptop with CAT ET installed and licensed (Version 2007A minimum) Communication Adaptor with diagnostic connector.
Flash File procedure:
Process:
1. Download the correct flash file from TMI or SISWeb.
2. Save the correct flash file to your local hard drive.
3. Connect to the ECM using Service Tool (CAT ET).
4. Make sure the ECM is powered up (Check that Red light on Comm. Adaptor is illuminated).
5. Go to "Winflash" or "Flash Memory".
6. CAT ET re-connect to the ECM.
7. Using the browse function in the top right hand corner, select the new flash file previously saved to hard drive.
8. Select "Begin Flash" (bottom right hand corner).
9. Once Flashing is complete select "CAT ET".
10. The Personality Module Mismatch should appear, select the ok button.
11. The factory password screen should now appear.
12. Use https://fps.cat.com to obtain factory passwords.
13. Enter Factory Passwords.
14. CAT ET High Level Configuration screen should be displayed.
15. Re-flash complete.