106671-0370 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-0370 1066710370

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Cross reference number

ZEXEL 106671-0370 1066710370

Zexel num

Bosch num

Firm num

Name

106671-0370

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 132424-0620

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 R2(11.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 154.3 150.3 158.3

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 12.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 174.4 172.4 176.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_03

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.1 9.1 11.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position R1(10.7)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 120.6 118.6 122.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position 12.3+0.2

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 173.8 163.8 183.8

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(10.7)

Boost pressure kPa 4

Boost pressure mmHg 30

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 12.3+0.2

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Timer adjustment

Pump speed r/min 200+100

Advance angle deg. 1.6 1.1 2.1

Remarks
Start

Timer adjustment_02

Pump speed r/min 500-150

Advance angle deg. 0 0 0

Timer adjustment_03

Pump speed r/min (900)

Advance angle deg. 0 0 0

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using stop lever (2)Damper spring setting: DL (3)Variable speed specification: idling adjustment (4)Main spring setting (5)Idle sub spring setting: L1. (6)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
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DL=6.4-0.2mm L1=7-0.2mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=31deg+-5deg b=(24deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At threaded hole above R = aa
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aa=17mm
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a=22deg+-5deg b=34.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa (2)Rack position bb
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aa=50mm bb=12.3+0.2mm
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a=30deg+-5deg b=32deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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----------
a=(30deg)

Information:

2. Remove two short bolts (1) and two longer bolts (2) from manifold (3) and BrakeSaver housing.3. Remove the manifold from the control valve. 4. Remove the three bolts from elbows (5) and the control valve.5. Remove four bolts (4) that hold the control valve to the oil pan.6. Remove the control valve from under the oil pan.7. Make an inspection of the O-ring seals on the manifold and on the control valve. If there is wear or damage make a replacement of the O-ring seals.Install Brakesaver Control Valve
1. Put clean SAE 30 engine oil on O-ring seals (1).2. Put the control valve in position under the oil pan. Install the four bolts that hold the control valve to the oil pan.3. Install the elbow and the bolts that hold it to the side of the control valve. 4. Put SAE 30 engine oil on the O-ring seals of the manifold. Install manifold (2) in the control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.5. Fill the engine with oil. See 3408 TRUCK ENGINE LUBRICATION AND MAINTENANCE GUIDE.Disassemble Brakesaver Control Valve
start by:a) remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.
Spring force is behind the cover at removal.
3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Make an inspection of the pin on the spool, and make a replacement of the pin if there is damage or wear.Assemble Brakesaver Control Valve
1. Install diaphragm (4) and plate (8) on valve spool (3). Make alignment of the hole in the plate valve with the pin on the spool. Install the bolt that holds the plate and the diaphragm in position.
When diaphragm (4) is installed on valve spool (3), make sure the fabric side is pulled down over the valve spool to make contact with it and the smooth (rubber coated) side is next to valve body.
2. Install sleeves (1) and the seals in the valve body. 3. Install the valve spool as an assembly into the valve body. As the valve spool is installed, make sure the edge of the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve spool end must extend about 1.50 in. (38.1 mm) from the valve body. Push the valve spool about .25 in. (6.4 mm) - .50 in. (12.7 mm) farther into the valve body until a curved depression is caused between the valve spool and valve body. Make sure there are no wrinkles in the diaphragm. 4. Put cover (9) in position. Install the four bolts that hold the cover on the valve body. Move the valve spool in the