106871-5011 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715011

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5011 1068715011

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Cross reference number

ZEXEL 106871-5011 1068715011

Zexel num

Bosch num

Firm num

Name

106871-5011

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 1-8-7-5- 4-3-6-2

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129.3 128.3 130.3

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 10.4 8.4 12.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 155

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1000

Advance angle deg. 1.9 1.4 2.4

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Torque control spring setting (3)Excess fuel setting for starting: SXL (N = N1) (4)Damper spring setting (5)Variable speed specification: idling adjustment (6)Fix the lever at the full-load position at delivery. (7)Main spring setting
----------
SXL=10.1+-0.1mm N1=450r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=(11deg)+-5deg b=5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=24.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=12deg+-5deg b=64deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.DEF injectors are being replaced in the field and returned to Caterpillar for testing. Results of the testing are finding a large portion of the returned DEF injectors are found to be fault not repeated.This form is to be used and filled out in any case that a DEF injector is being replaced.The DEF injector troubleshooting return form needs to be completed and included within failed part returns documenting what was found that led to DEF injector replacement. Attach the photos of DEF injector tip and mount area along with a Product Status Report to the SIMS claim.References
Table 1
Engine Publication Type Media Number
C7.1 Troubleshooting UENR0668
Testing and Adjusting UENR4467
Disassembly and Assembly UENR4468
C9.3 Troubleshooting UENR0978
Testing and Adjusting UENR3402
Disassembly and Assembly UENR0130
C13 Troubleshooting UENR0955
Testing and Adjusting UENR4302
Disassembly and Assembly UENR0131
C15/C18 Troubleshooting UENR0955
Testing and Adjusting UENR3351
Disassembly and Assembly UENR0132 Procedure
What code are you troubleshooting? __________
Follow the correct troubleshooting procedure. Reference Table 1 for correct media number to use.
When troubleshooting procedure requests the DEF quality check, DEF injector resistance measurement, or Dosing Accuracy Test, document those results in Tables 2, 3, and 4.Tables
Table 2
DEF Quality Results
Step Instruction Completed (Yes/No) Result Comments Units
1 Follow the Testing and Adjusting procedure for "Diesel Exhaust Fluid Quality - Test"
2 DEF Contamination Test Pass / Fail
3 DEF Concentration Test % at 20° C (68° F)
Illustration 1 g06175415
Table 3
Injector Resistance Measurement
Step Instruction Completed (Yes/No) Result Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injectors from the applicable harness.
3 Inspect the connector for damage and debris.
4 Measure the temperature of the injector (aluminum body). C
5 Connect two 398-4987 Probes to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector. Reference Illustration 1 for example.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed (Yes/No) Result Comments Units
1 Follow the Testing and Adjusting procedure for "Aftertreatment SCR System Dosing - Test"
2 Remove the injector from the DPF outlet.
3 Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
4 Install the injector on the beaker.
5 Run the DEF System Dosing Accuracy test through Cat® Electronic Technician (ET).
6 Use the beaker to measure the amount of fluid from the dosing test. ml
7 Repeat the test to verify consistency. ml
8 Install the injector back onto the DPF outlet.