108621-2024 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086212024

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108621-2024 1086212024

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Service parts 108621-2024 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-0011

3. GOVERNOR 105487-5740

4. SUPPLY PUMP 105237-1840

5. AUTOM. ADVANCE MECHANIS 105681-8010

6. COUPLING PLATE 105664-0650

7. COUPLING PLATE

8. _ 159590-4522

9. _

10. NOZZLE AND HOLDER ASSY 105101-7421

11. Nozzle and Holder ME120897

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105030-4461

14. NOZZLE 105015-8221

15. NOZZLE SET

Include in #1:

108621-2024 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108621-2024 1086212024

Zexel num

Bosch num

Firm num

Name

108621-2024

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 131424-7220

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

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

Digi switch no. 21

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 11.1

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 167.5 163.3 171.7

Basic *

Fixing the rack *

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_02

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 11.6 9.9 13.3

Fixing the rack *

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 167.5 166.5 168.5

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Injection quantity adjustment_04

Adjusting point B

Rack position R1-1.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 137.5 131.5 143.5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Injection quantity adjustment_05

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 165 145 185

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R2(R1-1. 6)

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(11.1)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min 640--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 590

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 840

Advance angle deg. 2 1.5 2.5

Remarks
Finish

0000001601

Pre-stroke mm 5.6 5.57 5.63

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 5 4.5 5.5

Remarks
When the eccentric pin is tightened

_03

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 1 1.05

Adjustment *

Remarks
Output voltage V1

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.6 2.32 2.88

Output voltage V 2.8 2.78 2.87

Confirmation *

_05

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)Boost compensator cancel stroke: BSL (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
BSL=1.8mm BCL=1.6+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=16deg+-5deg

0000000901

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

----------
a=8deg+-5deg b=33.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb (3)Drive side
----------
aa=37mm bb=2.5-0.5mm
----------
a=41.5deg+7deg-5deg b=(41.5deg)+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.6+-0.03mm
----------
a=(2deg)

0000002201 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=5.3+-0.1mm
----------

0000002301 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)
----------
N1=650r/min Ra=R1(11.1)mm
----------

Information:

Tooling, Test, and Bulk Ground Fill Support Equipment
Diesel Exhaust Fluid (DEF)
Two container sizes of DEF are available through the Cat® dealers in North America. DEF must meet ISO 22241-1 specifications.
Table 1
Tool Part Number Description
350-8733 Diesel Exhaust Fluid 9.5 L (2.5 US gal) bottle
350-8734 Diesel Exhaust Fluid 1378 L (364 US gal) tote
443-0955 Removal Tool DEF filter removal tool Dispensing Equipment
Three different dispensing kits are offered to protect DEF quality. Optional flow meter and coupler are also available.
Table 2
Tool Part Number Description
422-1185 Pump Adapter (DEF DISPENSER) 12 V dispenser unit
423-7843 Pump Adapter (DEF DISPENSER) 110 V dispenser unit
423-7844 Pump Adapter (DEF DISPENSER) 230 V dispenser unit with"smart start"tote base
423-7795 Flow Meter In line DEF flow meter
423-7799 Coupler MicroMatic coupler Dispenser Unit Repair Parts
Table 3
Tool Part Number Description
436-6643 Repair Kit 12 V dispenser unit
436-6646 Diesel Exhaust Fluid Pump 12 V repair group
436-6642 Hose 20'/4'
436-6644 Swivel
436-6645 Repair Kit 1/2 hp pump
436-6647 Nozzle (DIESEL EXHAUST FLUID) Dispensing nozzle Storage and Transportation
Preventing DEF contamination does not stop at the pump. Protect your DEF supply with climate-specific enclosures and transportation tanks.
Table 4
Part Number Description
435-8671 Dispenser Warm-weather enclosure
435-8672 Dispenser Cold-weather enclosure
460-4077 Tank 121 L (32 US gal)
460-4078 Tank 269 L (71 US gal) Fast Fill Vehicle Interface
Illustration 1 g06516654
584-9979 Nozzle As
Table 5
584-9979 Nozzle As
Repair parts for 584-9979 Nozzle As
- 587-3371 Rear Cap
- 587-3372 Handle
- 587-3373 Hose (3/4")
- 587-3374 O-Ring Seal
- 587-3375 Handle (optional)
459-9296 Receiver As (Permanently mounted on vehicle)
For heated DEF hose repair connectors, kits, and instructions , refer to Service Magazine, M0103829, "Repair Kits for Quick Connect Diesel Exhaust Fluid (DEF) Line Fittings Are Now Available for Certain Cat® Machine Engines". Testing Equipment
Test your DEF supply and DEF injector with DEF-specific testing equipment. Complete kits or individual testing components are available for your needs.
Table 6
441-0451 Tool Gp (includes hard case, foam insert, and hardware)
- 441-0454 Container
- 443-7055 Test Kit
- 398-4985 Probe
- 398-4987 Probe
- 398-5080 Lead
- 398-5081 Lead
- 398-5083 Plug
450-1515 Tool Gp (DIESEL EXHAUST FLUID) (includes hard case, foam insert, and hardware)
- 441-0454 Container
- 398-4985 Probe
- 398-4987 Probe
- 398-5080 Lead
- 398-5081 Lead
- 398-5083 Plug
441-0454 Container
443-7055 Test Kit
431-7087 Tool Gp (REFRACTOMETER (DEF))
360-0774 Refractometer
372-5260 Test Lead Tool Group
576-6134 Test Strip