106873-3061 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733061

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-3061 1068733061

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Cross reference number

ZEXEL 106873-3061 1068733061

Zexel num

Bosch num

Firm num

Name

106873-3061

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 4.5 4.44 4.5

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 9.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 157.6 155.6 159.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 160.7 157.7 163.7

Fixing the lever *

Injection quantity adjustment_03

Adjusting point E

Rack position 8.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 129 126 132

Fixing the lever *

Injection quantity adjustment_04

Adjusting point F

Rack position 3.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point G

Rack position 9.85+-0. 1

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 178.5 174.5 182.5

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 188 188 208

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 700--

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 4.75 4.45 5.05

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). (3)Excess fuel setting for starting: SXL (4)Damper spring setting
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N1=300r/min R1=3.9mm N2=1150r/min Q1=3mm3/st SXL=9.85+-0.1mm
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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=39mm
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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

Timing setting

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

----------
a=(80deg)

Information:

Bridge Adjustment
Intake and Exhaust Valve Mechanism
(1) Adjustment locknut, (2) Exhaust bridge, (3) Adjustment locknut, (4) Intake bridgeThe valve bridge should be checked and/or adjusted each time valve clearance is checked and/or adjusted. Valve and valve mechanism components do not always wear evenly which can allow the bridge to be out of adjustment.It is not necessary to remove the rocker arm shaft to adjust the valve bridges, but there must be clearance. Use the procedure that follows to make an adjustment to the bridge. Valves must be fully closed.1. Remove the valve covers from the engine.2. Lubricate the bridge dowel, bridge bore and the top pad of the bridge assembly with engine oil.3. While firmly pressing straight down on the bridge pad with a force of 1 to 10 lb (0.5 to 4.5 kg), turn the adjusting screw clockwise (CW) until contact is made with the valve stem.4. Turn the adjusting screw clockwise (CW) an additional 45° (1/8 turn) to straighten the dowel in the guide and compensate for slack in the threads.5. Hold the adjusting screw in this position and tighten the adjustment locknut to a torque of 18 5 lb ft (25 7 N m).6. Put engine oil at the point where the rocker arms make contact with the bridges.Valve Lash (Clearance) and Unit Injector Preload Adjustment
Valve clearance is measured between the rocker arm and the bridge for the valves.
Measure the valve lash with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool to engine cylinder head and block temperature.
When the valve lash (clearance) is checked, an adjustment is NOT necessary if the measurement is within the range given in the "Valve Clearance Check" chart shown. If the measurement is outside of the valve clearance check range shown, an adjustment is necessary. See the "Valve Clearance Setting" chart shown and make the setting to the nominal (desired) specifications in this chart. Adjust the valve clearance to within .003 in ( 0.08 mm) of the value given in the chart above.Rotate the engine crankshaft 360° in the normal crankshaft rotation direction before any adjustments are made. Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
Cylinder and Valve LocationTo make an adjustment to the valve clearance, turn the adjustment screw in the rocker arm. Valve clearance adjustments can be made by using the following procedure. The No. 1 piston must be at top center (TC) on the compression stroke. Follow the first three steps to find top center position for piston No. 1.
Locating Top Center for Piston No. 1
(1) Bolts (two - 6V5219), (2) Cover, (3) Flywheel Housing1. Remove two bolts (1) and remove cover (2) from the flywheel housing (3) to open the turning hole.2. Put one of the 6V5219 bolts in the timing hole located approximately 5 to 6 inches (127 to 152 mm) above the turning hole in