Information injection-pump assembly
ZEXEL
106961-6120
1069616120
ISUZU
1156029130
1156029130
Rating:
Service parts 106961-6120 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-204-1
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106961-6120
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106961-6120
1069616120
ISUZU
1156029130
1156029130
Zexel num
Bosch num
Firm num
Name
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 (drive side)
134424-4020
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
kgf/cm2
2.6
2.25
2.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-7-6-
5-4-3-10
-9-2
Pre-stroke
mm
4.4
4.37
4.43
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25
Cal 1-8 deg. 27 26.75 27.25
Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25
Cal 1-7 deg. 72 71.75 72.25
Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25
Cal 1-6 deg. 99 98.75 99.25
Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25
Cal 1-5 deg. 144 143.75 144.25
Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25
Cal 1-4 deg. 171 170.75 171.25
Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25
Cal 1-3 deg. 216 215.75 216.25
Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25
Cal 1-10 deg. 243 242.75 243.25
Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25
Cal 1-9 deg. 288 287.75 288.25
Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
7.9
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
100
98.5
101.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
112
108
116
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.5
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
109
107
111
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
-
Rack position
4.9+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
13.5
12.2
14.8
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
620--
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
570
Advance angle
deg.
0.3
Load
4/4
Timer adjustment_03
Pump speed
r/min
850+-30
Advance angle
deg.
2
1.5
2.5
Load
4/4
Timer adjustment_04
Pump speed
r/min
900
Advance angle
deg.
2
1.5
2.5
Load
3/4
Timer adjustment_05
Pump speed
r/min
1120
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Damper spring setting
(5)Confirm non-injection at point F (N = N1, after setting damper).
(6)Variable speed specification: idling adjustment
(7)Main spring setting
----------
RT=0.8 TH=2.5mm N1=1000r/min
----------
----------
RT=0.8 TH=2.5mm N1=1000r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Stopper bolt setting
(3)Use the hole at R = aa
----------
aa=150mm
----------
a=5.5deg+-5deg b=14deg+-5deg
----------
aa=150mm
----------
a=5.5deg+-5deg b=14deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=40mm
----------
a=10deg+-5deg b=32.5deg+-3deg
----------
aa=40mm
----------
a=10deg+-5deg b=32.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa (set timing)
(4)-
----------
aa=10deg
----------
a=(180deg)
----------
aa=10deg
----------
a=(180deg)
Information:
Introduction
This Special Instruction provides information to reset Diesel Particulate Filter (DPF) soot load on certain XQ60 rental generator sets.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
Reset Procedure for DPF Soot Load
Perform the following procedure to reset DPF soot load:
Turn the generator set battery disconnect to ON position.
Verify power to Electronic Modular Control Panel (EMCP).
Connect Cat® Electronic Technician (Cat ET) service tool.
Connect to Cat ET - Configuration EMCP Controller.
Update "RO#2" on EMCP from "Eng Start Initiated" to "Auto Mode".
Change the generator set to auto mode. Changing the generator set to auto mode applies power to engine Electronic Control Module (ECM).
Verify whether the active code in Cat ET is "3719-0 - High DPF Soot Load".
Illustration 1 g06574660
Electronic Modular Control Panel
Illustration 2 g06574661
Engine Electronic Control Module
Check whether the parameters shown in Illustration 1 and Illustration 2 are set in "EMCP" and "Engine ECM" configurations.
Illustration 3 g06574662
Perform DPF soot load reset by navigating "Component Replacement Resets".
Verify DPF Soot Load value in "Engine Status" screen.
Verify the active codes.
Stop the unit in EMCP.
Update "RO#2" from "Auto Mode" to "Eng Start Initiated".
Check whether the unit is set to run at idle speed in "EMCP".
Run the unit and check whether "low idle speed" is 1200 rpm. Refer to Illustration 3.
Manually
This Special Instruction provides information to reset Diesel Particulate Filter (DPF) soot load on certain XQ60 rental generator sets.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
Reset Procedure for DPF Soot Load
Perform the following procedure to reset DPF soot load:
Turn the generator set battery disconnect to ON position.
Verify power to Electronic Modular Control Panel (EMCP).
Connect Cat® Electronic Technician (Cat ET) service tool.
Connect to Cat ET - Configuration EMCP Controller.
Update "RO#2" on EMCP from "Eng Start Initiated" to "Auto Mode".
Change the generator set to auto mode. Changing the generator set to auto mode applies power to engine Electronic Control Module (ECM).
Verify whether the active code in Cat ET is "3719-0 - High DPF Soot Load".
Illustration 1 g06574660
Electronic Modular Control Panel
Illustration 2 g06574661
Engine Electronic Control Module
Check whether the parameters shown in Illustration 1 and Illustration 2 are set in "EMCP" and "Engine ECM" configurations.
Illustration 3 g06574662
Perform DPF soot load reset by navigating "Component Replacement Resets".
Verify DPF Soot Load value in "Engine Status" screen.
Verify the active codes.
Stop the unit in EMCP.
Update "RO#2" from "Auto Mode" to "Eng Start Initiated".
Check whether the unit is set to run at idle speed in "EMCP".
Run the unit and check whether "low idle speed" is 1200 rpm. Refer to Illustration 3.
Manually