108622-1220 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086221220 1156033600

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108622-1220 1086221220

ISUZU 1156033600 1156033600

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Cross reference number

ZEXEL 108622-1220 1086221220

ISUZU 1156033600 1156033600

Zexel num

Bosch num

Firm num

Name

108622-1220
108622-1221

1156033600 ISUZU

INJECTION-PUMP ASSEMBLY
6SD1-TCE * K

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 131424-7120

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. 32

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 8.5 8.47 8.53

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 12.9

Pump speed r/min 720 720 720

Average injection quantity mm3/st. 156.5 154.5 158.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.7+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 14.5 11.3 17.7

Max. variation between cylinders % 0 -13 13

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 8.4+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.9)

Pump speed r/min 720 720 720

Average injection quantity mm3/st. 156.5 154.5 158.5

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 141.5 131.5 151.5

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-1.7

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2[R1-1. 4]

Boost pressure kPa 40 40 40

Boost pressure mmHg 300 300 300

0000001601

Pre-stroke mm 8.5 8.47 8.53

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

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 6.1 6.05 6.15

Output voltage V 2.45 2.44 2.46

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 8.5 8.47 8.53

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.5

Output voltage V 3 2.98 3

Confirmation *

_06

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. (3)Boost compensator stroke: BCL
----------
T1=AF76 BCL=1.7+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=22.5deg+-5deg b=30deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=14deg+-5deg b=41deg+-5deg

0000001301

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove. (4)Damper (5)Pointer (6)B.T.D.C.: aa (7)Pre-stroke: bb
----------
aa=5deg bb=8.5+-0.03mm
----------
a=(50deg) b=(44deg)

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 counterclockwise (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 clockwise 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 TAMPER PROOF

SW:Inner hexagonal SW14 (F): Apply thread lock adhesive . (G): Full tamper proof (H): Full boost (Full rack) (I): 0 boost 1. Mount (C) and (D) after adjusting the boost compensator. 2. Back off the load lever set screw L1 from the end face of the governor housing.. 3. Apply boost pressure and set the full load at tamper set position point aa to obtain N1, Q1 and Ra using the screw C. 4. Fix using the nut (D). 5. Next, after adjusting the stop lever, confirm the point aa. 6. Reset the load lever to the full boost rack. 7. After completion of setting, seal using the plug (E).
----------
L1=6+1mm N1=1100r/min Ra=R1(12.9)+1.8mm Q1=(154)mm3/st aa=F
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T1=53.9~73.5N-m(5.5~7.5Kgf-m) T2=2.94~4.41N-m(0.3~0.45Kgf-m)

0000002301 TAMPER PROOF

(A): Rotation tamper proof (B): Full-speed setting 1. Back off the full-speed set bolt. 2. Confirm that the tamper setting position is N1, R1, Q1. 3. At that time, record the angle of the speed lever. 4. After confirming the above setting, set full speed.
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N1=1395r/min R1=(7.4)mm Q1=-
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0000002401 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(12.9)+1.1mm N1=1100r/min V1=3+-0.01V
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Information:

AUGUST 2011
INFORMATION RELEASE MEMO
Reman
PELJ1306 ?2011 Caterpillar REMAN DIESEL PARTICULATE FILTERS FOR MACHINE APPLICATIONS
To provide our customers with cost effective service options to support their Tier 4 emissions engines, Cat Reman has released a Reman version of the diesel particulate filters (DPF) used on many Tier 4 Cat? machines. The DPF traps both soot and ash. Soot is removed through a regeneration process outlined in the machines operation and maintenance manual. Ash that accumulates from engine oil is removed through a cleaning procedure that requires removal of the DPF from the machine. The cleaning procedure requires the DPF to be removed from the machine. Special Instruction REHS5045 outlines the three approved processes for performing the required Diesel Particulate Filter (DPF) maintenance on Tier 4 products equipped with a DPF.
Replacement of the existing DPF with a new Cat DPF
Replacement of the existing DPF with a remanufactured Cat DPF
Removal of the existing DPF and having the DPF cleaned by a Cat approved cleaning device.
The Reman DPFs listed below are available to support these maintenance requirements:
Core Acceptance
After gaining some experience with the previously released DPFs used for on-highway engines and to support the launch of these additional machine DPFs, we have changed some of the inspection criteria and issued a revision to SELD0292. SELD0292-02 Caterpillar Diesel Particulate Filter (DPF) is the current Core Acceptance Criteria (CAC). It is critical to avoid non-operational damage that can decrease the value of the cores. Encourage service technicians to handle and package the cores with care so they will be more likely to be eligible for the full core refunds. Please always refer to the most current version at catreman.cat.com/core to view the latest requirements. The acceptability inspection for these is a simple visual inspection based on the following guidelines:
Warranty
All Reman products carry the same warranty as new parts. Please consult the appropriate warranty statement for your area.
Core Management
Please refer to the Cat Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as Policy and Core Management SELD0122 -10, "Core Management Systems and Operations Procedures SELD0040-14, "Reman Core Return Packaging Instructions And Guidelines SELD0300-00 and "Shipping Instructions" SELD0039-14.
If you have any questions regarding Reman Core Management or Core Management Systems (CMIS2),