Information injection-pump assembly
ZEXEL
106671-2800
1066712800
Rating:
Service parts 106671-2800 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME056357
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106671-2800
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-2800
1066712800
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
131424-4620
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
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
1-5-3-6-
2-4
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
9.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
144
140.5
147.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
F
Rack position
5+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
144
143
145
Basic
*
Fixing the lever
*
Boost pressure
kPa
57.3
57.3
Boost pressure
mmHg
430
430
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.4)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
152.8
149.6
156
Difference in delivery
mm3/st.
6.4
6.4
6.4
Fixing the lever
*
Boost pressure
kPa
57.3
57.3
Boost pressure
mmHg
430
430
Injection quantity adjustment_05
Adjusting point
D
Rack position
9.3
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
139.5
135.5
143.5
Fixing the lever
*
Boost pressure
kPa
40
40
40
Boost pressure
mmHg
300
300
300
Injection quantity adjustment_06
Adjusting point
C
Rack position
5.7+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
(check)
(check)
Injection quantity adjustment_07
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
95
135
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
7.9
Boost pressure
kPa
6
6
6
Boost pressure
mmHg
45
45
45
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
8.55
Boost pressure
kPa
19.3
12.6
26
Boost pressure
mmHg
145
95
195
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
9.3
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Boost compensator adjustment_04
Pump speed
r/min
600
600
600
Rack position
R1(9.4)
Boost pressure
kPa
44
44
44
Boost pressure
mmHg
330
330
330
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)Boost compensator cancel stroke: BSL
(5)Boost compensator stroke
(6)Damper spring setting
----------
RT=1 TH=1.8mm BSL=2.2mm
----------
----------
RT=1 TH=1.8mm BSL=2.2mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=18deg+-5deg
----------
----------
a=18deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=28deg+-5deg b=30deg+-3deg
----------
----------
a=28deg+-5deg b=30deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at delivery)
----------
aa=4.1-0.5mm bb=13.3mm
----------
a=26deg+-5deg b=(38deg) c=0+7deg-5deg
----------
aa=4.1-0.5mm bb=13.3mm
----------
a=26deg+-5deg b=(38deg) c=0+7deg-5deg
0000001501 RACK SENSOR
V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1= 5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1= 5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
0000001601 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=5.4+-0.1mm
----------
----------
N1=325r/min Ra=5.4+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(7deg)
----------
----------
a=(7deg)
Information:
Literature Information
This manual contains recommended safety procedures, fluid systems specifications, operation instructions, maintenance information and basic troubleshooting along with basic repair information and should be stored in the pilot house or engine area. Read, study and keep it in a literature holder or literature storage area with other literature and engine information.Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult your Caterpillar dealer for the latest available information.Safety
The safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
Operating techniques outlined in this manual are basic to assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the pilot gains knowledge of the engine and its capabilities.The operation section is a reference for experienced pilots, and photographs and illustrations guide the new pilot through correct procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of gauges, indicators, features and controls.Maintenance
The maintenance section is a guide to engine care. Items in the Maintenance Schedule are referenced to detailed instructions that follow. The instructions and procedures are grouped by fuel consumption, service hours and/or calendar time maintenance intervals.Use fuel consumption first to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.Recommended service should always be performed at the fuel consumption interval first. The actual operating environment of the engine also governs the maintenance schedule. Therefore, under extremely severe or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Schedule may be necessary.Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record.See the Maintenance Records section in this manual for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar engine dealer can assist you in tailoring your Maintenance Schedule to meet the needs of your operating environment.Overhaul
Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure which necessitates removal of the engine from the hull, there are also numerous after failure overhaul options available from your Caterpillar dealer. Contact
This manual contains recommended safety procedures, fluid systems specifications, operation instructions, maintenance information and basic troubleshooting along with basic repair information and should be stored in the pilot house or engine area. Read, study and keep it in a literature holder or literature storage area with other literature and engine information.Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult your Caterpillar dealer for the latest available information.Safety
The safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
Operating techniques outlined in this manual are basic to assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the pilot gains knowledge of the engine and its capabilities.The operation section is a reference for experienced pilots, and photographs and illustrations guide the new pilot through correct procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of gauges, indicators, features and controls.Maintenance
The maintenance section is a guide to engine care. Items in the Maintenance Schedule are referenced to detailed instructions that follow. The instructions and procedures are grouped by fuel consumption, service hours and/or calendar time maintenance intervals.Use fuel consumption first to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.Recommended service should always be performed at the fuel consumption interval first. The actual operating environment of the engine also governs the maintenance schedule. Therefore, under extremely severe or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Schedule may be necessary.Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record.See the Maintenance Records section in this manual for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar engine dealer can assist you in tailoring your Maintenance Schedule to meet the needs of your operating environment.Overhaul
Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure which necessitates removal of the engine from the hull, there are also numerous after failure overhaul options available from your Caterpillar dealer. Contact