106651-0620 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066510620

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106651-0620 1066510620

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Service parts 106651-0620 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106065-1250

3. GOVERNOR 105407-3530

4. SUPPLY PUMP 105217-1730

5. AUTOM. ADVANCE MECHANIS 105614-0730

6. COUPLING PLATE 105662-0761

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4050

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4270

14. NOZZLE

105015-2780

15. NOZZLE SET

Include in #1:

106651-0620 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106651-0620 1066510620

Zexel num

Bosch num

Firm num

Name

106651-0620

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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-2-6- 3-5

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 11

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 108.6 107.6 109.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.6

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 81 79.5 82.5

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 7+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 15 13.9 16.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 500

Remarks
Measure the actual advance angle.

Timer adjustment_02

Pump speed r/min 700

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min 900

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2.5 1.9 2.7

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1.
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K=15 L1=7-0.5mm
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb.
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aa=900r/min bb=750r/min
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a=25deg+-5deg b=9deg+-5deg c=32deg+-3deg d=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
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a1=A a2=E r1=750r/min r2=750r/min Q1=108.6+-1mm3/st Q2=- c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min

Information:

Start By:a. remove valve covers1. Turn the flywheel with Tool (C) until there is clearance between the rocker arms and valve bridges. 2. Engage Tool (A) with the rocker arm, and move Tool (A) against the valve spring force until push rod (1) can be removed.3. Remove the other push rod for the same cylinder. Mark each push rod so it can be installed in its original position. 4. Use Tool (B) to remove valve lifter (2).5. Remove the other valve lifter for the same cylinder. Mark each valve lifter so it can be installed in its original position. 6. Remove spring (3) from lifter (2).7. Inspect spring (3). See Guideline For Reusable Parts, SEBF8066. 8. Identify the location of each valve bridge (4), then remove them.Install Push Rods, Valve Lifters & Valve Bridges
1. Put clean engine oil on each bridge dowel and the bore of each bridge. Install bridges (1) in their original position.2. Use the following procedure to adjust the valve bridges.a. Put clean SAE 30 Engine Oil in the lubrication passage of the bridge.b. Press straight down on the top contact surface of the bridge with a force of 4.45 to 44.50 N (1 to 10 lb).c. Turn the adjusting screw clockwise until the oil film in the lubrication passage of the bridge moves inward.d. Turn the adjusting screw an additional 20 to 30 degrees (1/3 to 1/2 of a flat on the hex nut).e. Hold the adjusting screw in position, and tighten the locknut to a torque of 26 to 34 N m (19 to 25 lb ft).f. Do this procedure for both bridges. Put clean engine oil on the top contact surface of both bridges. 3. Install spring (3) on valve lifter (2). 4. Fasten Tool (A) to valve lifter (2).5. Immerse valve lifter (2) in clean engine oil; then install it in its original position.6. Install the other valve lifter for the same cylinder. 7. Engage Tool (B) with the rocker arm, and move Tool (B) against the valve spring force until push rods (4) can be installed in their original position.8. Use Tool (C) to turn the flywheel so the remaining push rods can be installed. Be sure there is clearance at the rocker arms and valve bridges before compressing the valve pump.9. Check the valve clearance settings. The clearance for the intake valves is 0.38 mm (.015 in). The clearance for the exhaust valve is 0.76 mm (.030 in). See the topic "Valve Clearance Setting" in Testing & Adjusting.End By:a. install valve covers