106681-4451 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066814451 12788151980

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106681-4451 1066814451

YANMAR 12788151980 12788151980

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Cross reference number

ZEXEL 106681-4451 1066814451

YANMAR 12788151980 12788151980

Zexel num

Bosch num

Firm num

Name

106681-4451

12788151980 YANMAR

INJECTION-PUMP ASSEMBLY
6CZ-GT K 14CA INJECTION PUMP ASSY PE6P,6PD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000

Overflow valve 131425-1620

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Drive 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 14.9

Pump speed r/min 1150 1150 1150

Each cylinder's injection qty mm3/st. 424 411.3 436.7

Basic *

Fixing the lever *

Boost pressure kPa 112 112

Boost pressure mmHg 840 840

Injection quantity adjustment_02

Adjusting point B

Rack position 7.2+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 21.5 18.3 24.7

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 15.1++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 460 450 470

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-2.8

Boost pressure kPa 52 49.3 54.7

Boost pressure mmHg 390 370 410

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(14.9)

Boost pressure kPa 98.6 91.9 105.3

Boost pressure mmHg 740 690 790

Timer adjustment

Pump speed r/min 480--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 430

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 620

Advance angle deg. 2.5 2 3

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)RACK LIMIT (4)Boost compensator stroke: BCL
----------
K=6 BCL=2.8+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=100r/min
----------
a=12deg+-5deg b=37deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Normal (3)Rack position bb, pump speed cc (seal at delivery)
----------
aa=20mm bb=1-0.5mm cc=0r/min
----------
a=37deg+-5deg b=(73deg)

Timing setting

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

----------
a=(50deg)

Information:

Introduction
Do not perform any procedure that is outlined in the Special Instruction until the entire instruction has been read and understood.Check Valve Torque
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
The check valves that are located within the fuel pressure regulator group are sensitive to assembly torque. In order to eliminate the risk of valve distortion, torque the check valves to 28 3 N m (21 2 lb ft). Refer to Table 1 for the check valve part numbers that required the torque that is listed above.
Table 1
Part Number Description
327-0376 Check Valve Gp
327-4448 Check Valve Gp
281-2725 Check Valve Gp
282-1915 Check Valve Gp
228-7381 Check Valve Gp
327-8044 Check Valve Gp