106873-3043 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733043

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-3043 1068733043

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Cross reference number

ZEXEL 106873-3043 1068733043

Zexel num

Bosch num

Firm num

Name

106873-3043

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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 139.3 137.3 141.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.95+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 133.1 129.1 137.1

Fixing the lever *

Injection quantity adjustment_03

Adjusting point F

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.4 7.4 13.4

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 139 139

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 820--

Advance angle deg. 0.7 0.4 1

Load 4/4

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 0.7 0.4 1

Load 3/4

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 5.25 4.95 5.55

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting (6)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
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RT=0.8 TH=2.7mm SXL=9.45+-0.1mm N1=325r/min R1=3.8mm N2=1100r/min Q1=3mm3/st
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Speed control lever angle

F:Full speed
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a=15.5deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=42mm
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a=39deg+-5deg b=43.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (at delivery), set before governor adjustment (2)Set the stopper bolt (apply red paint). (3)Use the pin at R = bb (4)Lever free
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aa=12+-0.1mm bb=37mm
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a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=1100r/min Ra=(8.95)mm
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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=(80deg)

Information:

Engine Lifting
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling. To remove the engine, use the two lifting eyes on the engine.Lifting eyes are designed for the arrangement as sold. Alterations to lifting eyes and/or arrangement weight make the lifting devices obsolete.If you make alterations, you are responsible for providing adequate lifting devices.Engine Storage
If the engine is not started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings. Rust can form on the cylinder liner surface, which will increase engine wear and result in shorter engine life.To prevent excessive engine wear:
Be sure all lubrication recommendations mentioned in the Maintenance Management Schedule intervals chart are completed.If freezing temperatures can be expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar permanent-type antifreeze and approved water will give protection below -20°F (-29°C).If it will be impossible to start the engine every week, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.If an engine remains out of service and its use is not immediately planned, special precautions should be taken.Refer to "Storage Procedures For Caterpillar Products," Form SEHS9031 for more detailed information on engine storage.