106861-0880 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068610880

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106861-0880 1068610880

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Service parts 106861-0880 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106086-5620

3. GOVERNOR 105407-3520

4. SUPPLY PUMP 105217-1730

5. AUTOM. ADVANCE MECHANIS 105636-5030

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-4680

11. Nozzle and Holder 1660097003

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-3360

15. NOZZLE SET

Include in #1:

106861-0880 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106861-0880 1068610880

Zexel num

Bosch num

Firm num

Name

106861-0880

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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-5- 4-3-6-2

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 8.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 115.5 113.5 117.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.2

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 90.5 88.5 92.5

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.2+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 14.5 12.5 16.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 300+100

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 3 2.5 3.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 4.7 4.2 5.2

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 8 8 8

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1.
----------
K=13 L1=4.7-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=(23deg)+-5deg b=(9deg)+-5deg c=32deg+-3deg d=(7deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=A a2=E r1=750r/min r2=750r/min Q1=115.5+-2mm3/st Q2=- c1=+-4% c2=+-4% a3=18 a4=15 r3=900r/min r4=750r/min

Information:

Problem
The 9Y3222 Injector Rocker Arms may fail on certain 205B, 206B, 211B, 212B, 213B, 214B, 224B, and 325 Excavators; D20D and D250D Articulated Trucks; 446 Backhoe Loaders; 950F Loaders; 3114 Industrial Engines; 3116 Industrial Engines; 3116 Marine Engines; and 3116 Truck Engines. The arm may fail near the adjusting screw or the insert on the injector end of the arm may break.
Affected Product
Model & Identification Number
205B (5ZF1-91)
206B (9BF1-691)
211B (6XG1-162)
212B (3PJ1-912)
213B (1EJ1-378)
214B (4CF1-517; 9MF1-386)
224B (7WF1-181)
325 (2JK174-254)
D20D (9MG1-46)
D250D (6NG1-35)
446 (6XF1-689)
950F (6YG1-2729; 7ZF1-1045)
3114 (Industrial) (5EF1-974)
3116 (Industrial) (2WG1-2506; 4PG1-847)
3116 (Marine) (4KF1-1154)
3116 (Truck) (2BK10000-14485)
Parts Needed
6 - 9Y3222 Injector Arm AssemblyAction Required
If one 9Y3222 Injector Arm Assembly fails, follow the procedures in the Service Manual and replace all six 9Y3222 Injector Arm Assemblies.
In marine applications where there is more than one engine per vessel, install six new 9Y3222 Injector Arm Assemblies on all engines if there is a 9Y3222 Injector Arm Assembly failure.
Service Claim Allowances
All Affected Product Except Truck Engines
This is a 4-hour job.
Truck Engines
Labor segment for test after repair not allowed for this repair.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.