106873-3591 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733591


 

Information injection-pump assembly

ZEXEL 106873-3591 1068733591
106873-3591 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 106873-3591 1068733591


Zexel num
Bosch num
Firm num
Name
106873-3591 
 
   
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   131425-0020
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   4.2 4.14 4.2
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   12.5
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   119.5 116.5 122.5
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   H
Rack position   8.5+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   12 9 15
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(12.5)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   119.5 117.5 121.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.2
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   113 107 119
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.2
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   115 109 121
Fixing the lever   *
Timer adjustment
Pump speed r/min   680--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   630
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   (700)
Advance angle deg.   1 0.7 1.3
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   900+50
Advance angle deg.   1 0.7 1.3
Timer adjustment_05
Pump speed r/min   1100-50
Advance angle deg.   4.5 4.2 4.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106873-3591
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 RA (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=AC70 RA=18mm Ra=R1(12.5)+1.9mm
----------

Speed control lever angle

Test data 106873-3591
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=79mm
----------
a=12deg+-5deg b=26deg+-3deg

Stop lever angle

Test data 106873-3591
N:Pump normal S:Stop the pump. (1)Rack position = approximately aa. (2)Set the stopper screw. (After setting, apply red paint.) (3)Speed = bb, rack position = cc (4)Set the stopper screw. (After setting, apply red paint.) (5)Use the hole above R = dd
----------
aa=18mm bb=0r/min cc=1.5+-0.3mm dd=35mm
----------
a=35deg+-5deg b=15deg+-5deg

Timing setting

Test data 106873-3591
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Maintenance and operation practices affect component life in severe service applications.Scheduled Oil Sampling (S O S)
Caterpillar's Scheduled Oil Sampling (S O S) is the best indicator for determining what is happening inside your engine.S O S is a diagnostic tool used to determine oil performance and component wear rates with a series of tests designed to identify and measure contamination such as soot, sulfur, etc. and degradation such as the presence of fuel, water and antifreeze in a sample of oil.The tests also determine the amount of wear metals present in the oil sample, which is compared to established Caterpillar norms to determine acceptability. To be effective as an indicator, S O S must be performed on a continuing basis. Intermittent sampling will not allow wear rate trend lines to be established.Obtain S O S samples at regularly scheduled intervals to monitor the condition and maintenance requirements of your engine. Each oil sample should be taken when the oil is warm and well mixed to ensure that the sample is representative of the oil in the engine crankcase and oil pan.Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine(s).S O S Analysis
S O S is composed of three basic tests:* Wear Analysis* Chemical and Physical Tests* Oil Condition Analysis Wear Analysis is performed with an atomic absorption spectrophotometer to monitor component wear by identifying and measuring concentrations, in parts per million, of wear elements present in the oil. Based on known normal concentration data, maximum limits of wear elements are established. Impending failures can be identified when test results deviate from concentration levels established as acceptable, based on normal wear. Chemical and Physical Tests detect the presence of water, fuel and glycol (antifreeze) in the oil and determine whether or not their concentrations exceed established maximum limits. Oil Condition Analysis is evaluated with infrared analysis (IR). This test determines the presence and measures the amount of contaminants such as soot, sulfur products, oxidation, and nitration products in the oil. Infrared analysis can also assist in customizing (reducing, maintaining or extending) oil change intervals for particular conditions and applications.Infrared analysis should always be accompanied by wear element analysis and chemical and physical tests to assure accurate diagnosis. Infrared analysis must be used to determine oil change intervals. S O S must include Infrared (IR) in the analysis.The test results of the oil samples will then be used as a basis for determining the oil change interval for your engine, giving you the ultimate time between oil changes without the risk of engine damage.Refer to Caterpillar pamphlet Scheduled Oil Sampling, form PEDP7105 for information and benefits of S O S.Obtain Sample
Each oil sample should be taken when the oil is warm and well mixed to ensure that the sample is representative of the oil in the crankcase.There are two methods recommended to obtain S O S samples from the engine. * Use the sampling valve, if installed on the engine,

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Group cross 106873-3591 ZEXEL

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INJECTION-PUMP ASSEMBLY

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