106691-0541 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066910541

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106691-0541 1066910541

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Service parts 106691-0541 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-7420

3. GOVERNOR 105407-5361

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105681-0391

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6170

11. Nozzle and Holder 16600-96511

12. Open Pre:MPa(Kqf/cm2) 22.6{230}

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5800

15. NOZZLE SET

Include in #1:

106691-0541 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106691-0541 1066910541

Zexel num

Bosch num

Firm num

Name

106691-0541

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 132424-0620

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 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 1-4-2-6- 3-5

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 144 142 146

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_02

Adjusting point E

Rack position 4.6+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 13.7 12.7 14.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position 9.2

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 10.7+-0. 1

Boost pressure kPa 14.7 10.7 18.7

Boost pressure mmHg 110 80 140

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position (11.3)

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Timer adjustment

Pump speed r/min 980--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 930

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1050

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed, stop

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)Boost compensator stroke: BCL (4)Excessive fuel lever setting (boost pressure 0) (5)Set idle sub-spring (6)Main spring setting (7)Rack difference between N = N1 and N = N2
----------
K=9 BCL=(2.1)mm N1=1050r/min N2=650r/min
----------

Speed control lever angle

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

----------
a=(3deg)+-5deg b=(15deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa (at boost pressure = bb)
----------
aa=10.7+-0.1mm bb=0kPa(0mmHg)
----------
a=(8deg) b=(18deg)

Timing setting

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

----------
a=(20deg)

Information:

*******Group 2*******
C18 N8F00529-00532, 534-535, 542-545
PARTS NEEDED
Qty
Part Number Description
*******Group 1*******
6 20R3454 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% 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.
*******Group 2*******
6 20R3454 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% 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
If a single injector fails, replace all six injectors at the time of failure. Refer to Disassembly and Assembly, UENR0132, "Valve Mechanism Cover - Remove and Install" and "Electronic Unit Injector - Remove and Install" to complete the repair.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-6000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-6000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.