106971-0690 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069710690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-0690 1069710690

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Service parts 106971-0690 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5380

3. GOVERNOR 105487-4000

4. SUPPLY PUMP 105237-1860

5. AUTOM. ADVANCE MECHANIS 105681-0201

6. COUPLING PLATE 105662-0602

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7700

11. Nozzle and Holder 16600-97070

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105031-4790

14. NOZZLE

105015-6810

15. NOZZLE SET

Include in #1:

106971-0690 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-0690 1069710690

Zexel num

Bosch num

Firm num

Name

106971-0690

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 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 10-9-4-3 -6-5-8-7 -2-1

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 10-9 deg. 45 44.5 45.5

Difference between angles 2
Cal 10-4 deg. 72 71.5 72.5

Difference between angles 3
Cal 10-3 deg. 117 116.5 117.5

Difference between angles 4
Cal 10-6 deg. 144 143.5 144.5

Difference between angles 5
Cal 10-5 deg. 189 188.5 189.5

Difference between angles 6
Cal 10-8 deg. 216 215.5 216.5

Difference between angles 7
Cal 10-7 deg. 261 260.5 261.5

Difference between angles 8
Cal 10-2 deg. 288 287.5 288.5

Difference between angles 9
Cal 10-1 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point A

Rack position 10.3

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 129.4 128.4 130.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 9 13

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 6.7+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 10 8 12

Fixing the rack *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Load 3/4

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Rack limit using the stop lever: R1 (4)Excess fuel setting for starting: SXL (5)Damper spring setting: DL (6)Variable speed specification: idling adjustment (7)Main spring setting
----------
RT=1 TH=1.5mm R1=12.4+0.2mm SXL=10.3+0.2mm DL=6.5-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Stopper bolt setting
----------
aa=290r/min
----------
a=(7deg)+-5deg b=(13deg)+-5deg

0000000901

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

----------
a=18.5deg+-5deg b=26deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=12.4+0.2mm
----------
a=4.5deg+-5deg b=30deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the start of injection for the No. 10 cylinder. (3)- (4)-
----------

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

Information:

ACTION REQUIRED
Flash engine ECM with new 422-8397 Software on machines located in North America.
Flash engine ECM with new 422-8398 Software on machines located in Europe.
Refer to Special Instruction, REHS7927 for instructions on replacing the diesel particulate filter pressure lines group.
Refer to Special Instruction, REHS7197 for instructions on installing the engine cooling fan bypass feature.
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*******
0-5000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 12.0-hour job for Group 1
Travel and Mileage will be allowed for this program
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-5000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 12.0-hour job for Group 2
Travel and Mileage will be allowed for this program
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.