Information injection-pump assembly
ZEXEL
106691-4111
1066914111
Rating:
Cross reference number
ZEXEL
106691-4111
1066914111
Zexel num
Bosch num
Firm num
Name
106691-4111
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4120
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.75
3.7
3.8
Rack position
Point A or more. R=A
Point A or more. R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
137.5
135.5
139.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
37.3
37.3
Boost pressure
mmHg
280
280
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.5+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
21
19.5
22.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
E
Rack position
11.9++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
160
150
170
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
10.1
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
11.15
Boost pressure
kPa
24
24
24
Boost pressure
mmHg
180
180
180
Timer adjustment
Pump speed
r/min
(N1+50)-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N1
Advance angle
deg.
0.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
2
1.7
2.3
Remarks
Measure the actual speed, stop
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)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2
----------
K=16 BCL=1.05+-0.1mm N1=1000r/min N2=500r/min
----------
----------
K=16 BCL=1.05+-0.1mm N1=1000r/min N2=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=69mm
----------
a=(9deg)+-5deg b=(28deg)+-5deg
----------
aa=69mm
----------
a=(9deg)+-5deg b=(28deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb (stamp at delivery)
(2)Normal
----------
aa=1-0.5mm bb=0r/min
----------
a=33deg+-5deg b=70deg+-5deg
----------
aa=1-0.5mm bb=0r/min
----------
a=33deg+-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=8deg
----------
a=(140deg)
----------
aa=8deg
----------
a=(140deg)
Information:
Remote Fault Reset$00 $0D aUsed to reset faults on the CCM.
Table 2
(a) $00 - $7F = Retain current CCM inactive fault status.
$80 - $FF = Reset CCM inactive fault. Device ID Code$00 $80 aabbccUsed to read the device ID code from the CCM as well as other components on the data link. Each pair of bytes (aa, bb, cc) is sent LSB first.
Table 3
(aa) Module ID: will always equal $61, data will be sent as $61 $00
(bb) Service Tool Support Change Level: $01, data will be sent as $01 $00
(cc) Application type:$FF $E0, data will be sent as $E0 $FF CCM Error Codes$00 $82 abUsed to read the CCM Error Codes.
Table 4
(a) bit 1 = Reserved
(b) (1) Fault Code Status
bit 8 1 = RS-232C link message fault exists
bit 7 1 = Miscellaneous Cat Data Link fault
bit 6 1 = Invalid Cat Data message fault
bit 5 1 = Internal buffer overflow on RS-232C or Data Data Link fault
bit 4 1 = RS-232C short circuit fault
bit 3 1 = Memory battery is weak
bit 2 1 = M5X message error (checksum or byte count error)
bit 1 1 = EEPROM fault
( 1 ) A value of 0 (zero) in bits 1 through 8 indicates that particular fault does not exist.CCM Communication Rate Change Enable$AA $12 aUsed to determine if the CCM is connected to the host computer directly or remotely using a modem. Also used to enable or disable the host computers ability to change the communication rate of the RS-232C serial port.
Table 5
(a) Bit 4 Reserved for Caterpillar.
Bit 3 0 = Enable password protection
1 = Disable password protection
Bit 2 0 = Enable baud rate change
1 = Disable baud rate change
Bit 1 0 = Direct connection
1 = Modem connection Access Level 1 Password$AA $87 aaaaaaaaUsed to read or program the Level 1 Password
Table 6
(aaaaaaaa) Level 1 password in printable ASCII form. Must be at least 6, but no more than
Table 2
(a) $00 - $7F = Retain current CCM inactive fault status.
$80 - $FF = Reset CCM inactive fault. Device ID Code$00 $80 aabbccUsed to read the device ID code from the CCM as well as other components on the data link. Each pair of bytes (aa, bb, cc) is sent LSB first.
Table 3
(aa) Module ID: will always equal $61, data will be sent as $61 $00
(bb) Service Tool Support Change Level: $01, data will be sent as $01 $00
(cc) Application type:$FF $E0, data will be sent as $E0 $FF CCM Error Codes$00 $82 abUsed to read the CCM Error Codes.
Table 4
(a) bit 1 = Reserved
(b) (1) Fault Code Status
bit 8 1 = RS-232C link message fault exists
bit 7 1 = Miscellaneous Cat Data Link fault
bit 6 1 = Invalid Cat Data message fault
bit 5 1 = Internal buffer overflow on RS-232C or Data Data Link fault
bit 4 1 = RS-232C short circuit fault
bit 3 1 = Memory battery is weak
bit 2 1 = M5X message error (checksum or byte count error)
bit 1 1 = EEPROM fault
( 1 ) A value of 0 (zero) in bits 1 through 8 indicates that particular fault does not exist.CCM Communication Rate Change Enable$AA $12 aUsed to determine if the CCM is connected to the host computer directly or remotely using a modem. Also used to enable or disable the host computers ability to change the communication rate of the RS-232C serial port.
Table 5
(a) Bit 4 Reserved for Caterpillar.
Bit 3 0 = Enable password protection
1 = Disable password protection
Bit 2 0 = Enable baud rate change
1 = Disable baud rate change
Bit 1 0 = Direct connection
1 = Modem connection Access Level 1 Password$AA $87 aaaaaaaaUsed to read or program the Level 1 Password
Table 6
(aaaaaaaa) Level 1 password in printable ASCII form. Must be at least 6, but no more than
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106691-4111
INJECTION-PUMP ASSEMBLY