106871-5080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715080

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5080 1068715080

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Service parts 106871-5080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5380

3. GOVERNOR 105489-4010

4. SUPPLY PUMP 105237-6020

5. AUTOM. ADVANCE MECHANIS 105683-0120

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7040

11. Nozzle and Holder 16600-97078

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}

13. NOZZLE-HOLDER 105041-4020

14. NOZZLE 105015-9240

15. NOZZLE SET

Include in #1:

106871-5080 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5080 1068715080

Zexel num

Bosch num

Firm num

Name

106871-5080

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 3.9 3.85 3.95

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 10.6

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 138.9 137.9 139.9

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point E

Rack position 6.2+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 9.5 7.5 11.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1000

Remarks
Measure the actual advance angle.

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting (4)Variable speed specification: idling adjustment (5)Fix the lever at the full-load position at delivery. (6)Main spring setting
----------
SXL=11.1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=12deg+-5deg b=7.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=28.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the pin at R = aa
----------
aa=28mm
----------
a=12deg+-5deg b=64deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

Table 1
Features Benefits
All engineering changes and updates included Improved reliability and performance
Worldwide availability through the Cat® Parts Distribution System Customer access regardless of location
Off the shelf reliability Downtime reduced through exchanged product
Same as new Caterpillar warranty Consistent support
Illustration 1 g06211468
(1) Rocker arm with MEUI-C hardware
(2) Rocker arm with MEUI-A hardwareNote: The 192-4151 Button is being replaced with the 258-8721 Button on MEUI-A injector rocker arms. Either button can be used for both types of injectors.
Table 2
MEUI-C Rocker MEUI-A Rocker
258-8721 Button 192-4151 Button
274-4492 Arm Adjustment Screw 196-5069 Arm Adjustment Screw
8L-2777 O-Ring Seal 061-8639 O-Ring Seal
Table 3
Reman Part Number New Part Number Machine Serial Number Prefixes
20R-3319 437-3881 221, 530, 819, 880, 986, 1DL, 1XJ, 24W, 25W, 26W, 27W, 2TW, 2YD, 3F6, 3KR, 3SK, 45P, 4SK, 5TJ, 5TW, 6AB, 6PR, 6YF, 6XJ, 6YZ, 7MZ, 86Z, 87X, 87Z, 9TC, A4G, A9P, AKA, AMA, ANS, APF, ARW, ASW, AWW, AYT, AZW, B1N, BCC, BKX, BLY, BRL, BTW, BTX, BXD, BXY, BYP, CMX, DBB, DBC, DHF, DHJ, DHT, DHX, DJK, DLS, DLW, DN6, DNM, DNR, DNW, DR3, DS3, DS9, DW9, E4S, EDA, EED, EXD, EYG, FCT, FDL, FEN, FKD, GEB, GT7, GXR, H25, H4C, H8M, H9K, HJD, HS2, JCM, JET, JJW, JLK, JMS, JNS, JNW, JRP, JXP, KBC, KCZ, KDH, KDP, KGB, KK2, KK3, KLK, KLS, KNW, KPZ, KSD, KZL, L4F, LFJ, LFK, LFN, LTX, LWY, MB8, MBE, MCY, MDG, MFL, MKP, MWH, MYA, NEL, NNW, P4J, P4L, PAR, PAX, PJA, PT7, RAB, RCD, RCY, RFM, RLB, RM2, RM3, RMA, RME, RWB, SEE, SET, T2F, T4P, T4S, T4Y, T5S, T5W, TFJ, TNM, TWA, TWG, TYE, W1B, W1F, WBT, WSN, WT6, WTW, WTX, WWC, WWD, Z4D, Z4Z, ZAC, ZMX
20R-3322 437-3862 232, 233, 234, 818, 1AB, 1FB, 1NB, 1JB, 2GB, 2KR, 2PS, 2SR, 2XW, 3ND, 47M, 5EW, 5YR, 6BK, 6GZ, 6TB, 6TR, 71W, 7CG, 7KR, 7XM, 85X, 86X, 8PS, 90Z, A7A, A8J, ALP, ANW, AP4, ASX, AT2, AW4, AWF, AWH, AWR, AXB, AXF, AXG, AXM, AYH, AZZ, B1P, B1R, B93, B9K, BBB, BDS, BKF, BNH, BPC, BWX, BZZ, CB2, CEN, CES, CEX, CLD, CLS, CXM, CXR, DBD, DFA, DFJ, DHB, DHD, DHG, DHL, DP4, DPE, DT8, DWJ, DXB, DXE, DXG, DXR, E4R, EAM, EBF, ECM, ECX, ELC, FAT, FH9, FMC, GAY, GER, GLH, GLK, GWC, GXM, H27, HSM, J2M, J8B, JKC, JR8, KEX, KJW, KKJ, KKK, L4D, L4E, L8S, LH9, LTS, LWA, LWX, LWZ, M1M, M3P, M3W, M4E, MB9, MCS, MEM, MEX, MH8, MHG, MLN, MMA, MNZ, MSE, MSF, N64, NFJ, NLK, P1C, P1M, PAP, PAS, PF8, PNM, RCM, RJG, RJS, SBE, SJY, T2E, T4R, TAS, TEC, TLB, TPB, TWZ, W1C, W1E, WAG, WAP, WAW, WTK, XP8, Z4X, Z9K
Table 4
Reman Part Number New Part Number Engine Serial Number Prefixes
20R-3319 437-3881 115, 127, 132, 137, 173, 174, 175, 2A3, 3LW, 5DS, 7CZ, 8AZ, 9NN, 9YP, AL6, AN2, AR2, AR3, ASW, AT4, AZW, B2C, B3G, BEM, BFM, BGA, BXS, C1G, C2T, C4G, C5E, C5L, C6C, CAH, CCB, CE5, CKH, CWJ, DCT, DDS, DGK, DGL, DKE, DSJ, DWB, E1Y, GB3, GBM, GDS, GEN, GES, GRS, GSZ, GTB,