106671-1763 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066711763

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-1763 1066711763

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Service parts 106671-1763 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7910

3. GOVERNOR 105407-4872

4. SUPPLY PUMP 105207-1480

5. AUTOM. ADVANCE MECHANIS 105635-0390

6. COUPLING PLATE 105662-0990

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6672

11. Nozzle and Holder 1-15300-289-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-9071

15. NOZZLE SET

Include in #1:

106671-1763 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-1763 1066711763

Zexel num

Bosch num

Firm num

Name

106671-1763

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 134424-1920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.67 3.73

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 134.3 132.3 136.3

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 5.2+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 14.5 11.3 17.7

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the stopper bolt (at shipping).
----------

----------
a=(22deg)+-5deg b=(0deg)+-5deg c=43deg+-3deg

Stop lever angle

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

----------
a=8.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(50deg)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Disconnect pressure line (3). Remove two bolts (2).2. Move fuel ratio control (1) up to disengage the fuel ratio control from the lever assembly in the governor. 3. Remove four O-ring seals (4) and screen assembly (5). The following steps are to install the fuel ratio control.4. Inspect, replace and install the four O-ring seals (4) and the screen assembly (5).5. Put the fuel ratio control (1) in position and engage the fuel ratio control with the lever assembly in the governor.6. Install the bolts that hold the fuel ratio control and connect pressure line (3) to the fuel ratio control (1). See Testing And Adjusting for Fuel Ratio Control Adjustment procedure.Disassemble And Assemble Fuel Ratio Control
Start By:a. remove fuel ratio control
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the two bolts, and the fuel ratio control. Remove O-ring seal (1). 2. Put tooling (A) in a vise as shown so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in tooling (A). Remove cover (2) and the gasket.
There is spring force behind cover (3). Hold cover (3) in position, and slowly remove the bolts that hold it to release the spring force.
3. Remove cover (3). 4. Remove nut (5) and stop (6). 5. Remove spring (9), washer (7), and diaphragm (10) from retainer (8). Remove retainer (8) from housing (11). 6. Remove nut (16) from extension (15), and remove the extension from retainer (8). Remove valve (12), spring (13) and O-ring seal (14). 7. Remove spring (18), retainer (17) and spring (19). 8. Remove piston assembly (20). 9. Use tooling (B), and remove snap ring (21) and the wave washers from valve assembly (22). Remove piston assembly (23). Remove seal (24). 10. If necessary, remove stem (26) from valve (25).11. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. The following steps are to assemble the fuel ratio control.12. Assemble stem (26) to valve (25) using 9S3265 Retaining Compound.13. Put seal (24) on piston (23). Install piston (23) on valve assembly (22).14. Put two wave washers in position on valve (22). Use tooling (B) to install the snap ring on the valve assembly.15. Place housing (4) on tooling (A), and put tooling (C) into the bore of the housing. Lubricate tooling (C) with clean engine oil.16. Put a small amount of clean oil on the seal of the piston assembly, and push piston assembly (23) into position with a smooth swift motion.17. Place spring (9), retainer (17) and spring (19) in position in housing (4).18. Put O-ring seal (14) on extension (15). Put spring (13) and valve (12) in position on the extension.19. Lubricate O-ring seal (14) with clean engine oil. Install extension (15) in retainer (8). Install nut