106671-0380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-0380 1066710380

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Cross reference number

ZEXEL 106671-0380 1066710380

Zexel num

Bosch num

Firm num

Name

106671-0380

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 R2(11.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 158.6 154.6 162.6

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_02

Adjusting point B

Rack position 12.1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 170.1 168.1 172.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

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(10.9)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 126.5 124.5 128.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position 12.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 176.1 166.1 186.1

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(10.9)

Boost pressure kPa 4

Boost pressure mmHg 30

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 12.5

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

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 820

Advance angle deg. 0.5

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy). (2)Rack limit using stop lever (3)Damper spring setting: DL
----------
DL=6.4-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=30deg+-5deg

0000000901

F:Full load I:Idle (1)At threaded hole above R = aa (2)Stopper bolt setting
----------
aa=17mm
----------
a=22deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa (2)Rack position bb
----------
aa=50mm bb=12.5mm
----------
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)-
----------

----------
a=(30deg)

Information:

start by:a) remove oil pump1. Remove bolt and washer that hold gear on the shaft. 2. Use tooling (A) to remove drive gear (1) from shaft. Remove the key from shaft. 3. Remove retainer (3) for bypass valve.4. Remove spring and bypass valve.5. Remove the cover (2) from pump body. 6. Use tooling (B) to remove bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) to remove bearings from pump body.Assemble Oil Pump
1. Use tooling (A) to install the bearings in the main pump body until they are even with the outside surface of the pump body. Install the bearings so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage (2) as shown. 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean oil on the bearings and gears. 3. Use tooling (A) to install the bearings in cover (4) until they are even with the outside surface of the cover. Install the bearings so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage as shown. 4. Install bypass valve (5), spring (6), spacer and the retainer in the pump body.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that holds the gear on the shaft.7. Make sure the pump turns freely by hand after it is assembled.end by:a) install oil pump