106871-4042 ZEXEL 9 400 618 128 BOSCH INJECTION-PUMP ASSEMBLY 9400618128 1068714042 33100mf110c

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 128 9400618128

ZEXEL 106871-4042 1068714042

HYUNDAI 33100MF110C 33100mf110c

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Buy INJECTION-PUMP ASSEMBLY 106871-4042 zexel genuine, new aftermarket engine parts with delivery

Service parts 106871-4042 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5600

3. GOVERNOR 105487-5360

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105636-0770

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7431

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7(180)/21.6(220)

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE

105015-7310

15. NOZZLE SET

Include in #1:

106871-4042 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 128 9400618128

ZEXEL 106871-4042 1068714042

HYUNDAI 33100MF110C 33100mf110c

Zexel num

Bosch num

Firm num

Name

106871-4042

9 400 618 128

33100MF110C HYUNDAI

INJECTION-PUMP ASSEMBLY
8DC9 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

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 134424-1320

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 1-2-7-3- 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 8.8

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 97 94.1 99.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point F

Rack position 5.8+-0.5

Pump speed r/min 450 450 450

Each cylinder's injection qty mm3/st. 17 15.3 18.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(8.8)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 105.7 101.5 109.9

Difference in delivery mm3/st. 8.4 8.4 8.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Remarks
(check)

Injection quantity adjustment_06

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 95 175

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.8 1.1 2.5

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 3.5 3.5

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting (6)When air cylinder is operating.
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SXL=9.4+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc (4)Air cylinder's adjustable range
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aa=1200r/min bb=275r/min cc=800r/min
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a=(13deg) b=8deg+-5deg c=13deg+-5deg d=23deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=23.5deg+-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)
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aa=4-0.5mm bb=11.7mm
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a=43deg+7deg-5deg b=21.5deg+-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
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N1=325r/min Ra=5.6+-0.1mm
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0000001601 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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Timing setting

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

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a=(40deg)

Information:

Installation Procedure
Illustration 1 g06124125
Remove plate (1) and discard. Save the hardware and hook assembly (2) for reuse.
Illustration 2 g06124137
(3) 5I-3822 Plate
Weld plate (3) in the location specified in Illustration 2.
Illustration 3 g06124150
Remove two hoses (4).
Illustration 4 g06124157
(5) 467-9635 Hose
(6) 428-8808 Hose Clamp
(7) 418-2057 Hose
(8) 467-9634 Hose
(9) 5P-4924 Elbow
(10) 6V-3250 O-Ring Seal
(11) 424-1209 Tank
Install hose (7) and two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install one end of hose (5) on the coolant tube and the other on tank (11). Secure the hose using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install elbow (9) and O-ring (10) onto tank (11). Tighten the elbow to 28 4 N m (21 3 lb ft).
Install hose (8) as shown using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Ensure the hoses connected to the tank are in parallel as shown in view D-D.
Illustration 5 g06124173
(12) 326-4516 Cable Tie
(13) 454-4235 Plate
Secure the hoses as shown using two cable ties (12) and plate (13).
Illustration 6 g06124183
(14) 511-8273 Sheet As
Install sheet (14) and hook assembly (2) using the saved hardware.
Illustration 7 g06124176
(11) 424-1209 Tank
(15) 467-9640 Plate As
(16) 8T-4136 Bolt
(17) 8T-4121 Hard Washer
(18) 8T-4189 Bolt
(19) 8T-4224 Hard Washer
Install plate assembly (15) using three bolts (16) and three washers (17).
Mount tank (11) onto plate (15) using two bolts (18) and two washers (19).
Install new machine, engine, and after treatment software. The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). SIS web only displays the latest available flash file.
Illustration 8 g06123932
Update the DES threshold to 525 degrees C using Cat® Electronic Technician (Cat ET). A factory password is required to change the value. A factory password can be obtained after inputting your Corporate Web Security (CWS) identification.