106671-0651 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710651

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-0651 1066710651

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Service parts 106671-0651 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5300

3. GOVERNOR 105487-3751

4. SUPPLY PUMP 105217-1730

5. AUTOM. ADVANCE MECHANIS 105636-1810

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5600

11. Nozzle and Holder 1660096520

12. Open Pre:MPa(Kqf/cm2) 22.6(230)

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE

105015-6340

15. NOZZLE SET

Include in #1:

106671-0651 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-0651 1066710651

Zexel num

Bosch num

Firm num

Name

106671-0651

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 12.1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 164 162 166

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_02

Adjusting point B

Rack position 12.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 155.6 149.6 161.6

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_03

Adjusting point C

Rack position 10.4

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 116.5 112.5 120.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position 12.4+-0. 1

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 166 156 176

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_05

Adjusting point E

Rack position 8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 16 15 17

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position 10.4

Boost pressure kPa 5.3

Boost pressure mmHg 40

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 11.2

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position 12.4+-0. 1

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Timer adjustment

Pump speed r/min 875--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 825

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 925

Advance angle deg. 1 0.5 1.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator stroke: BCL (5)Rack limit using the stop lever: R1 (6)Damper spring setting (7)Variable speed specification: idling adjustment (8)Fix the lever at the full-load position at delivery. (9)Main spring setting (10)Set idle sub-spring (11)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
RT=1 TH=1.7mm BCL=(2)mm R1=12.4+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=275r/min
----------
a=24deg+-5deg b=16.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=22deg+-5deg b=30.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb (3)Drive side
----------
aa=50mm bb=12.4+-0.1mm
----------
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 pistons1. Drain the coolant from the block. 2. Remove the liners from the block with tooling (A).
Be careful not to cause damage to the block or the piston cooling tubes when the cylinder liner is removed with tooling (A).
3. Remove the O-rings from the bottom of the liner. Remove