106873-3342 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733342


 

Information injection-pump assembly

ZEXEL 106873-3342 1068733342
106873-3342 INJECTION-PUMP ASSEMBLY
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Service parts 106873-3342 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106080-5751
3. GOVERNOR 105923-1202
4. SUPPLY PUMP 105237-0080
5. AUTOM. ADVANCE MECHANIS 105683-0390
6. COUPLING PLATE 105664-2170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7802
11. Nozzle and Holder 23600-2750A
12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}
13. NOZZLE-HOLDER 105030-3591
14. NOZZLE
15. NOZZLE SET 105019-0550

Include in #1:

106873-3342 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106873-3342 1068733342


Zexel num
Bosch num
Firm num
Name
106873-3342 
 
   
INJECTION-PUMP ASSEMBLY
14CD PE8P PE

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   134424-4120
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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 3.94 4
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   -
Rack position   12.8
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   140 137 143
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8+-0.5
Pump speed r/min   420 420 420
Average injection quantity mm3/st.   15.9 12.9 18.9
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.8)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   140 138 142
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.3
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   126 120 132
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-1.1
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   138 132 144
Fixing the lever   *
Timer adjustment
Pump speed r/min   710--
Advance angle deg.   0 0 0
Load   2/5
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   660
Advance angle deg.   0.3
Load   2/5
Timer adjustment_03
Pump speed r/min   (760)
Advance angle deg.   2 1.7 2.3
Load   5/5
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   900+50
Advance angle deg.   2 1.7 2.3
Load   4/5
Timer adjustment_05
Pump speed r/min   1100-50
Advance angle deg.   5.75 5.45 6.05
Load   5/5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106873-3342
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Stop lever's normal position setting: equivalent to R1 (4)Damper spring setting (5)Set stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point I (Ra) can be obtained at full setting.]
----------
T1=AC10 R1=17.5mm Ra=(12.8)+0.9mm
----------

Speed control lever angle

Test data 106873-3342
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=94mm
----------
a=17deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 106873-3342
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Set the stopper screw. (After setting, apply red paint.) (3)Rack position = bb (speed = cc) (4)Set the stopper screw. (After setting, apply red paint.) (5)Use the hole above R = dd
----------
aa=(17.5)mm bb=1.5+-0.3mm cc=0r/min dd=35mm
----------
a=35deg+-5deg b=15deg+-5deg

Timing setting

Test data 106873-3342
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:


The vehicle must be parked on a level surface to perform this maintenance procedure.
1. Check the oil leve with the engine stopped. 2. Maintain the oil leve between the ADD and FULL marks in the FULL RANGE zone on the ENGINE STOPPED side of the dipstick. Do not fill the crankcase above the FULL RANGE zone. Operating your engine when the oil level is above the FULL RANGE zone could cause your crankshaft to dip into the oil. If this happens, the air bubbles created from the crankshaft dipping into the oil will reduce the lubricating characteristics of your oil and would result in the loss of power.If the dipstick does not have a FULL mark in the FULL RANGE zone, refer to calibrating the oil level gauge in the Dipsticks section of this manual or consult your Caterpillar dealer before operating the engine. 3. Add oil if necessary. See Refill Capacities and Lubricant Specifications for the size of your engine crankcase and proper oil to use. Remote mounted or auxiliary filters require additional oil. For all information pertaining to auxiliary filters, refer to the OEM or manufacturer's instructions.Leaks and Loose Connections
Inspect the Engine
For maximum service life of your truck engine, make a thorough under the hood inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn fan belts, loose connections and trash build-up. Remove trash build-up and have repairs made as needed.Keep a close watch for leaks. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more frequently than the recommended intervals prescribed in this publication. Continue monitoring fluid levels until a leak is found and fixed, or until the suspicion for a leak has been proven to be unwarranted.* Wipe all fittings, caps and plugs before servicing. * Inspect the radiator for leaks and trash build-up. * Inspect the radiator hoses for cracks and loose clamps. * Inspect the fan and accessory drive belts for cracks, breaks or other damage.Belts for multiple groove pulleys must be replaced as matched sets. If only one belt of a 2 or 3 belt set is replaced, it will carry more of a load than the belts not replaced since the older belts are stretched. The additional load on the new belt could cause it to break. * Inspect the water pump for leaks. Check weep hole for water pump breather filter, 4N1400 (1), blockage and replace if necessary. * Inspect the engine for oil leaks, such as front and rear crankshaft seals, oil pan, oil filters and valve covers. * Inspect the fuel system for leaks, loose fuel line clamps and fittings and loose or worn hoses. * Inspect wiring for loose connections and worn or frayed wires. * Inspect air intake system hoses and elbows for cracks and loose clamps. * Inspect engine-to-frame ground strap for good connection and condition.* All guards must be in place. Repair or replace missing or

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