106671-5020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715020

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-5020 1066715020

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Service parts 106671-5020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5920

3. GOVERNOR 105407-4530

4. SUPPLY PUMP 105237-1800

5. AUTOM. ADVANCE MECHANIS 105636-2090

6. COUPLING PLATE 105663-0640

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6210

11. Nozzle and Holder 16600-95501

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

13. NOZZLE-HOLDER 105030-4310

14. NOZZLE 105015-8160

15. NOZZLE SET

Include in #1:

106671-5020 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5020 1066715020

Zexel num

Bosch num

Firm num

Name

106671-5020

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 3.9 3.85 3.95

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 8.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 114.6 112.6 116.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_02

Adjusting point B

Rack position 8.4

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 104 100 108

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_03

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8 7 9

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(8.5)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 100.6 97.6 103.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 350 350 350

Rack position R1(8.5)

Boost pressure kPa 12.7 10 15.4

Boost pressure mmHg 95 75 115

Boost compensator adjustment_02

Pump speed r/min 350 350 350

Rack position R1+0.4

Boost pressure kPa 25.3 21.3 29.3

Boost pressure mmHg 190 160 220

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1.8 1.8 1.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure)
----------
K=18 L1=9.8+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle
----------

----------
a=16deg+-5deg b=18deg+-5deg

Stop lever angle

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

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

0000001101

N:Normal B:When boosted (1)Rack position = aa
----------
aa=9.8+-0.1mm
----------
a=(6deg) b=(18deg)

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:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=6mm
----------
a1=B a2=- a3=- a4=- r1=700r/min r2=- r3=- r4=- Q1=114.6+-2mm3/st Q2=- Q3=- Q4=- c1=+-4% c2=- c3=- c4=- a5=22 a6=21 a7=20 a8=19 a9=18 a10=17 a11=16 a12=15 a13=14 a14=13 a15=- r5=1100r/min r6=1050r/min r7=1000r/min r8=950r/min r9=900r/min r10=850r/min r11=800r/min r12=750r/min r13=700r/min r14=650r/min r15=- R5=1200+-20r/min R6=1150+-20r/min R7=1100+-20r/min R8=1020+-23r/min R9=965+-22r/min R10=915+-22r/min R11=860+-20r/min R12=805+-18r/min R13=750+-17r/min R14=695+-16r/min R15=-

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=17deg
----------
a=(40deg)

Information:

Overcooling
25. Defective Temperature GaugeIf the temperature gauge shows that the coolant temperature is below normal and all other conditions indicate that conditions are normal, check the coolant temperature in another method, such as:* Read the coolant temperature with an ECAP or DDT.* Install an 8T0470 Thermistor Thermometer Group* Install a temperature sensitive tape.* Install a new gauge that is known to be good.26. Defective Coolant Temperature SensorIf a fault is detected in the coolant temperature sensor circuit, determine if the fault is in the wiring or the coolant temperature sensor following the procedure in Electronic Troubleshooting, 3176 Diesel Truck Engine, Form No. SENR3913. Repair or replace parts as needed. The coolant temperature sensor should be accurate within plus or minus 3° C (6° F). Check the accuracy of the sensor if it is found to be out of specification.27. Long Idle PeriodsRunning the engine for extended periods of time under no load conditions will cause the engine heat to be removed at a faster rate than it is being generated.28. Very Light LoadsVery light loads, very slow speeds, or downhill travel can cause below normal heating due to the decreased amount of fuel that is being burned. The installation of shutters will help correct this problem by decreasing the flow of air into the engine compartment.29. Defective Water Temperature RegulatorIf the water temperature regulator is stuck open, it will cause below normal engine heating. To test the thermostat, see the topic, Testing The Cooling System, in the Testing and Adjusting section of Systems Operation, Testing and Adjusting, Form No. SENR3909.30. Faulty Fan Clutch (Will Not Disengage)Check for proper operation of the fan clutch. Refer to the Truck Manufacturer's Service Manual for the proper procedure.31. Vent Line OpenIf the vent line (OEM) between the temperature regulator and the radiator top tank is open, overcooling could result. Install a valve assembly in the line that will allow air venting but restrict coolant flow with the engine running.