106861-2270 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068612270


 

Information injection-pump assembly

ZEXEL 106861-2270 1068612270
106861-2270 INJECTION-PUMP ASSEMBLY
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Service parts 106861-2270 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106086-5430
3. GOVERNOR 105487-3280
4. SUPPLY PUMP 105237-1321
5. AUTOM. ADVANCE MECHANIS 105636-1510
6. COUPLING PLATE 105663-0260
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5891
11. Nozzle and Holder ME066565
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}
13. NOZZLE-HOLDER 105030-4980
14. NOZZLE 105015-5510
15. NOZZLE SET

Include in #1:

106861-2270 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106861-2270 1068612270


Zexel num
Bosch num
Firm num
Name
106861-2270 
106861-2271 
 
  MITSUBISHI
INJECTION-PUMP ASSEMBLY
8DC9T0 *

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   131424-4620
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-2-7-3- 4-5-6-8
Pre-stroke mm   4.8 4.75 4.85
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   45 44.5 45.5
Difference between angles 2
Cal 1-7
deg.   90 89.5 90.5
Difference between angles 3
Cal 1-3
deg.   135 134.5 135.5
Difference between angles 4
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 5
Cal 1-5
deg.   225 224.5 225.5
Difference between angles 6
Cal 1-6
deg.   270 269.5 270.5
Difference between angles 7
Cal 1-8
deg.   315 314.5 315.5
Injection quantity adjustment
Adjusting point   -
Rack position   11.3
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   137 132.9 141.1
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   18.5 16 21
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.3)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   137 136 138
Basic   *
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_04
Adjusting point   D
Rack position   11.3
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   130 126.3 133.7
Fixing the lever   *
Boost pressure kPa   12.7 12.7 12.7
Boost pressure mmHg   95 95 95
Injection quantity adjustment_05
Adjusting point   E
Rack position   -
Pump speed r/min   200 200 200
Average injection quantity mm3/st.   120 100 140
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   400 400 400
Rack position   9.9
Boost pressure kPa   2 2 2
Boost pressure mmHg   15 15 15
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   11.3
Boost pressure kPa   12.7 11.4 14
Boost pressure mmHg   95 85 105
Boost compensator adjustment_03
Pump speed r/min   400 400 400
Rack position   (12.5)
Boost pressure kPa   20 20 20
Boost pressure mmHg   150 150 150
Timer adjustment
Pump speed r/min   980--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   (900)
Advance angle deg.   0 0 0
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106861-2270
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Boost compensator cancel stroke: BSL (4)Boost compensator stroke: BCL (5)Damper spring setting: DL
----------
RT=1 TH=2.7mm BSL=1.6mm BCL=1.4+-0.1mm DL=5.8-0.2mm
----------

Speed control lever angle

Test data 106861-2270
F:Full speed
----------

----------
a=18deg+-5deg

0000000901

Test data 106861-2270
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=32.5deg+-3deg

Stop lever angle

Test data 106861-2270
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at shipping)
----------
aa=4.7-0.5mm bb=15.3mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)

0000001501 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=325+-5r/min Ra=6.7mm
----------

Timing setting

Test data 106861-2270
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




Information:

Lubrication Specifications
Crankcase Lubricating Oils
Use oils which meet Engine Service Classification CD (MIL-L-2104D) or CD/TO-2. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines.Consult the "EMA Lubricating Oils Data Book," Form SEBU5939, for a listing of CD oil brands.The proper SAE grade of oil to select is determined by the ambient temperature at which the engine is started and the maximum ambient temperature in which the engine will be operating. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly.Lubricating Grease
Use Multipurpose-type Grease (MPGM) which contains 3-5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 0 or No. 1 Grade for extremely low temperatures.Recommended Lubricant Viscosities
Air Starting Motor Oiler: Use SAE 10W in all temperatures.Flywheel Clutch Bearing Reservoir: Use SAE 30 in all temperatures. Fuel Specifications
No. 2 fuel oil and No. 2D diesel fuel are recommended for use in Caterpillar Diesel Engines. In extreme cold temperatures use No. 1 fuel oil or No. 1D diesel fuel.In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to a vaporous state and condensed, thus eliminating all sediment and residue.There is considerable variation in the composition of fuels distributed under the No. 2 grade classifications. For desirable engine service it is most important to give special attention to cetane no., water and sediment, pour point, cloud point and sulphur content. USE THE LOWEST PRICE DISTILLATE FUEL WHICH MEETS THE FOLLOWING REQUIREMENTS.Water and Sediment 0.1% sedimentCetane No. (PC Engine) 35 minimum(DI Engine) 40 minimumPour Point 10°F (6°C) below ambient temperatureCloud Point No higher than ambient temperatureSulphur Content* Adjust oil change periodGravity 32-40 A.P.I. at 60°F (15.6°C)*See the topic SULPHUR CONTENT. Cetane No: This is an indication of a fuel's ignition quality and should not be less than 35 for the PC engine and 40 for the DI engine. For high altitude operation or cold weather starting, a higher cetane number is required. Water and Sediment: A good clean fuel will contain no more than 0.1% sediment and water. Dirty fuels lead to early filter plugging and in addition can result in the formation of gums and resins reducing filter and engine life. Pour Point: The pour point of the fuel has no effect on engine performance, as long as the fuel is fluid enough to flow from the fuel tank to the engine. The pour point of the fuel should be at least 10°F (6°C) below the lowest atmospheric temperature at which the engine must start and operate. In extremely cold temperatures it may be necessary to use No. 1 fuel oil or No. 1D diesel fuel. Cloud Point: Cloud point is the temperature at which wax crystals become visible and is generally above the pour point of

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