Information injection-pump assembly
ZEXEL
106873-7292
1068737292
Rating:
Service parts 106873-7292 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME093733
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
106873-7292
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106873-7292
1068737292
Zexel num
Bosch num
Firm num
Name
106873-7292
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-7-3-
4-5-6-8
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.5
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
115
111.5
118.5
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
430
430
430
Each cylinder's injection qty
mm3/st.
19
16.1
21.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
115
114
116
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
117
113
121
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.6
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
111
107
115
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Damper spring setting
----------
T1=AC73
----------
----------
T1=AC73
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(10deg) t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(10deg) t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=45mm
----------
a=3deg+-5deg b=39deg+-3deg
----------
aa=45mm
----------
a=3deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
(3)Normal engine position (Rack position corresponding to dd)
----------
aa=45mm bb=1100r/min cc=3+-0.3mm dd=18mm
----------
a=(31deg)+-5deg b=25.5deg+-5deg c=41deg+-5deg
----------
aa=45mm bb=1100r/min cc=3+-0.3mm dd=18mm
----------
a=(31deg)+-5deg b=25.5deg+-5deg c=41deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=335r/min Ra=7.9+-0.1mm
----------
----------
N1=335r/min Ra=7.9+-0.1mm
----------
0000001601 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)
----------
N1=1100r/min Ra=R1(11.5)+0.9mm
----------
----------
N1=1100r/min Ra=R1(11.5)+0.9mm
----------
0000001701 LEVER
Speed lever cancel adjustment procedure (without dashpot)
(A) Top lever
(B) Bottom lever
(C) Return spring
1. At governor adjustment (FULL adjustment)
(1)Set high idle using the lever (A).
(2)Confirm that lever (A) is not cancelled with lever (B).
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=4deg
----------
a=(50deg)
----------
aa=4deg
----------
a=(50deg)
Information:
USE FUEL CONSUMPTION, SERVICE HOURS OR TIME INTERVAL, WHICHEVER OCCURS FIRST.Daily
Walk-Around Inspection - Inspect engine, radiator and generator/control panel for dirt & debris, moisture, foreign objects, loose or broken fittings and wires, guards and components. Repair as necessary Engine Crankcase - Check oil level Cooling System - Check coolant level, Check for proper operation of coolant heater Air Cleaner Indicator - Check Air Starting Motor (If Equipped) - Check level; Drain water SR4 Generator - Check frequency (rpm) and generated voltage for proper settings and stability; record readingsEvery 250 Hours or 25 000 L (6500 gal) of Fuel*
Scheduled Oil Sampling (S O S)** - Obtain Engine Oil and Filters - Replace Fuel System - Drain water & sediment from tank; Replace final filter/Clean primary filter Cooling System - Test for coolant additive concentration; Add liquid coolant additive; Clean radiator fins Crankcase Breathers - Clean Batteries - Clean/Inspect and check electrolyte level Belts, Hoses and Clamps - Inspect/Check Engine Air Cleaners - Clean/Replace SR4 Generator - Check space heater (if equipped) Engine Speed Sensors (Magnetic Pickup) - Inspect/Clean at first oil change Valve Lash** - Check/Adjust at first oil changeEvery 1000 Hours or 100 000 L (26,000 gal) of Fuel*
Engine Protection Controls - Inspect for proper operation SR4 Generator - Check windings and record megohmeter readings (Refer to SEHS9124)Every 3000 Hours or 300 000 L (78,000 gal) of Fuel*
Engine Valve Lash - Check/Adjust, Inspect valve rotators Turbocharger - Inspect for proper operation Engine Mounts and Crankshaft Vibration Damper - Inspect/Check Cooling System - Clean/Flush/Change coolant and replace thermostat SR4 Generator - Lubricate bearings (Refer to SEBU6150) PAR Analysis - ObtainEvery 5000 Hours or 500 000 L (130,000 gal) of Fuel*
Fuel Injection Nozzles - Test/Exchange Starting Motor and Alternator - Inpect for proper operation Turbochargers - Inspect/Rebuild or Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Engine Speed Sensors (Magnetic Pickup) - Inspect/CleanOverhaul Every 10,000 Hours or 1 000 000 L (260,000 gal) of Fuel*
Cylinder Heads, Oil Pump, Fuel Transfer Pump - Inspect/Rebuild or Exchange Piston Rings, Main Bearings, Rod Bearings, Valve Rotators and Crankshaft Seals - Install new Fuel Injection Nozzles and Fuel Injection Pump - Test Connecting Rods, Pistons, Cylinder Liners, Crankshaft, Camshaft, Cam Bearings, Damper, Fuel Pump Camshaft, Cam Followers and Fuel Racks - Inspect/Replace Gear Train Gears & Bushings and Driven Unit Alignment Oil Cooler and Aftercooler Core - Clean/Test Coolant Analysis - Obtain SR4 Generator - Inspect/Clean windings*First Perform Previous Service Hour Items Caterpillar suggests that fuel consumption be used as the preferred method of determining maintenance intervals. Fuel consumption/Hours to Overhaul interval will vary depending on the proper application of your engine rating and maintenance practices.
Walk-Around Inspection - Inspect engine, radiator and generator/control panel for dirt & debris, moisture, foreign objects, loose or broken fittings and wires, guards and components. Repair as necessary Engine Crankcase - Check oil level Cooling System - Check coolant level, Check for proper operation of coolant heater Air Cleaner Indicator - Check Air Starting Motor (If Equipped) - Check level; Drain water SR4 Generator - Check frequency (rpm) and generated voltage for proper settings and stability; record readingsEvery 250 Hours or 25 000 L (6500 gal) of Fuel*
Scheduled Oil Sampling (S O S)** - Obtain Engine Oil and Filters - Replace Fuel System - Drain water & sediment from tank; Replace final filter/Clean primary filter Cooling System - Test for coolant additive concentration; Add liquid coolant additive; Clean radiator fins Crankcase Breathers - Clean Batteries - Clean/Inspect and check electrolyte level Belts, Hoses and Clamps - Inspect/Check Engine Air Cleaners - Clean/Replace SR4 Generator - Check space heater (if equipped) Engine Speed Sensors (Magnetic Pickup) - Inspect/Clean at first oil change Valve Lash** - Check/Adjust at first oil changeEvery 1000 Hours or 100 000 L (26,000 gal) of Fuel*
Engine Protection Controls - Inspect for proper operation SR4 Generator - Check windings and record megohmeter readings (Refer to SEHS9124)Every 3000 Hours or 300 000 L (78,000 gal) of Fuel*
Engine Valve Lash - Check/Adjust, Inspect valve rotators Turbocharger - Inspect for proper operation Engine Mounts and Crankshaft Vibration Damper - Inspect/Check Cooling System - Clean/Flush/Change coolant and replace thermostat SR4 Generator - Lubricate bearings (Refer to SEBU6150) PAR Analysis - ObtainEvery 5000 Hours or 500 000 L (130,000 gal) of Fuel*
Fuel Injection Nozzles - Test/Exchange Starting Motor and Alternator - Inpect for proper operation Turbochargers - Inspect/Rebuild or Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Engine Speed Sensors (Magnetic Pickup) - Inspect/CleanOverhaul Every 10,000 Hours or 1 000 000 L (260,000 gal) of Fuel*
Cylinder Heads, Oil Pump, Fuel Transfer Pump - Inspect/Rebuild or Exchange Piston Rings, Main Bearings, Rod Bearings, Valve Rotators and Crankshaft Seals - Install new Fuel Injection Nozzles and Fuel Injection Pump - Test Connecting Rods, Pistons, Cylinder Liners, Crankshaft, Camshaft, Cam Bearings, Damper, Fuel Pump Camshaft, Cam Followers and Fuel Racks - Inspect/Replace Gear Train Gears & Bushings and Driven Unit Alignment Oil Cooler and Aftercooler Core - Clean/Test Coolant Analysis - Obtain SR4 Generator - Inspect/Clean windings*First Perform Previous Service Hour Items Caterpillar suggests that fuel consumption be used as the preferred method of determining maintenance intervals. Fuel consumption/Hours to Overhaul interval will vary depending on the proper application of your engine rating and maintenance practices.
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106873-7292
INJECTION-PUMP ASSEMBLY