106682-9860 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066829860


 

Information injection-pump assembly

ZEXEL 106682-9860 1066829860
106682-9860 INJECTION-PUMP ASSEMBLY
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Service parts 106682-9860 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106068-3360
3. GOVERNOR 105447-2021
4. SUPPLY PUMP 105237-4910
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2390
7. COUPLING PLATE 156639-4420
8. _
9. _
10. NOZZLE AND HOLDER ASSY
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 26.0{265}
13. NOZZLE-HOLDER
14. NOZZLE
15. NOZZLE SET

Include in #1:

106682-9860 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106682-9860 1066829860


Zexel num
Bosch num
Firm num
Name
106682-9860 
 
   
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   105780-8130
Bosch type code   EFEP215A
Nozzle   105780-0050
Bosch type code   DN6TD119NP1T
Nozzle holder   105780-2090
Bosch type code   EFEP215
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-4-1000
Overflow valve   131425-1320
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)
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   3.5 3.45 3.55
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   15.5
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   410 407 413
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Boost pressure kPa   131 131
Boost pressure mmHg   980 980
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.4+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   8 6 10
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R1-3.9
Boost pressure kPa   30.7 28 33.4
Boost pressure mmHg   230 210 250
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R1(15.5)
Boost pressure kPa   117 110.3 123.7
Boost pressure mmHg   880 830 930

Test data Ex:

Governor adjustment

Test data 106682-9860
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator stroke: BCL (3)Stop lever at stopping (with the stop lever at full)
----------
K=13 BCL=3.9+-0.1mm
----------

Speed control lever angle

Test data 106682-9860
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=90mm
----------
a=1deg+-5deg b=36deg+-5deg

Stop lever angle

Test data 106682-9860
N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

Test data 106682-9860
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(150deg)




Information:

Your truck may not have the same or all of the gauges as shown in the illustrations. The illustrations shown are of typical gauges.Gauges provide a "look" inside the engine. Be sure they are in good working order. You can determine what is the "normal" operating range by observing your gauges over a period of time.Noticeable changes in gauge readings are indicative of potential gauge or engine problems. This also applies to gauge readings that have changed significantly but are still within specifications. The cause of any sudden or significant change in the readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be between 40 and 88 psi (275 and 606 kPa) when the engine is running at rated engine speed, with SAE 15W-40 oil, at operating temperature. A lower pressure is normal at low idling speed.
If no oil pressure is indicated, stop the engine. Engine damage can result.
Water Temperature - Indicates engine coolant temperture. It should normally indicate between 170°F (77°C) and 208°F (98°C). Somewhat higher temperature may occur under certain conditions. Maximum allowable temperature is 210°F (99°C) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).With the engine running, during normal operation, if the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge, have the charging system checked for malfunction. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding when downshifting, goin downhill, etc., can result in serious damage to your engine.
Do not exceed maximum braking rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. Electrically operated, it registers only when the key switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 23 psi (160 kPa) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of clock hours the engine has operated.

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