107691-2124 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912124

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2124 1076912124

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Cross reference number

ZEXEL 107691-2124 1076912124

Zexel num

Bosch num

Firm num

Name

107691-2124

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 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-8420

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

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 17

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.3

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 102.5 100.5 104.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 465 465 465

Average injection quantity mm3/st. 14 12.2 15.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.3)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 102.5 101.5 103.5

Basic *

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.5

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 102 98 106

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position R1-1.3

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 91 87 95

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1470

Advance angle deg. 3 2.5 3.5

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
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T1=AC46
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Accelerator lever
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aa=38mm
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a=29deg+-5deg b=39.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Normal engine position (equivalent to R = bb). (3)Set the stopper bolt at rack position = cc and speed = dd and confirm non-injection
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aa=47mm bb=17.4mm cc=3.5+-0.3mm dd=0r/min
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a=4deg+-5deg b=(31deg) c=41deg+-5deg

0000001301

(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)Pre-stroke: bb
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aa=5deg bb=5.6+-0.03mm
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a=(0deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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0000001701

A : Stopper pin B: Connector
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0000001801

C:Shim
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0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000002201 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=1450r/min Ra=R1(12.3)+1.5mm
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0000002301 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
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L=0.8~1mm
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Information:

Illustration 4 g01341045
(6) Temperature Sensor
(7) Pressure Sensor
Mount the 271-7350 Warning Indicator Module Gp in a place that is easy to view. Ensure that the ambient temperature is below 45 °C (113 °F), and ensure that the Warning Indicator Module is not directly exposed to high pressure steam cleaning, solvents, the battery off gas, or electrical discharge. Note: The LED display panel may be installed in the cab of the vehicle.
Illustration 5 g01341118
(8) LED display panel
(9) ECM Installation for the Wiring Harness
The 274-7578 Monitor Electronic Control Module is provided with a 307-5521 Wire Harness.
Connect the 70 pin AMP to the ECM using a 160-7690 Connector Plug As. Tighten the Connector Screw for the ECM to 6 1 N m (4 0.73 lb ft).
Locate a 12 VDC or 24 VDC power supply that is always available even when the key is turned "OFF".
Connect the power wires from the wiring harness to the power supply. Install a 15 AMP fuse in this circuit. If an additional wire must be spliced, use a 14 gauge wire.
Attach the appropriate connectors to the pressure sensor, the temperature sensor, and the lamp group. Note: The service tool that is used in this installation is Caterpillar Electronic Technician (CAT ET). The service tool connector is a 9 pin Deutsch connector that contains the CDL (Caterpillar Data Link)/ATA, CAN/J1939, and power. A connection from the 274-7578 Monitor Electronic Control Module to the PC requires a Caterpillar Communications adapter, which connects to the PC via a serial port.The service tool (CAT ET) supports the following functions:
Download and review active alarms and logged alarms
Clear active alarms
View the data in real time.
Flash the diagnostic module.
Provide the capability for the user to configure certain parameters.Software Configuration
Refer to Systems Operation, Troubleshooting, Testing and Adjusting, KENR6695 for a description of controllable parameters and operation instructions.Once the 274-7578 Monitor Electronic Control Modulehas power, the 274-7578 Monitor Electronic Control Module will begin monitoring the pressure sensors and the temperature sensors.
Check whether CAT ET is configured with English or Metric units.
Set CAT ET to Metric units if a Metric unit is not already selected. Specifications
Table 3
System Requirements
Requirements for 12VDC or 24VDC System Value Notes
Operating Voltage Minimum +9V Minimum continuous operating voltage without damage to the ECM
Maximum Operating Voltage +32V Maximum continuous operating voltage without damage to the ECM
The voltage is over the maximum voltage that is allowed (two minutes continuous). +80V At 25 °C (77 °F)
Reverse Voltage (one hour) -32V At 85 °C (185 °F)
Power up voltage for the ECM +9V The minimum voltage for the ECM to internally run. Operating the engine at this voltage will cause the damage to the ECM.
The maximum current draw with key switch off 10mA
Maximum current draw with zero engine speed and no loads being driven 500mA
Maximum continuous operating current draw 10A This highly dependent upon the number and type of loads driven by the ECM
Recommended size for the Battery Fuse. 15A
Table 4
Operating Conditions
Thermal Conditions Vibrations Humidity Tolerance Salt Spray Tolerance Moisture Leakage Chemical Splash Immunity Electrostatic Environment
Operating Temperature Range: