106671-5063 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715063

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-5063 1066715063

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Service parts 106671-5063 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0450

3. GOVERNOR 105487-5330

4. SUPPLY PUMP 105217-1850

5. AUTOM. ADVANCE MECHANIS 105636-2110

6. COUPLING PLATE 105663-0640

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6970

11. Nozzle and Holder 16600-96605

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

13. NOZZLE-HOLDER 105030-4540

14. NOZZLE 105015-8860

15. NOZZLE SET

Include in #1:

106671-5063 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5063 1066715063

Zexel num

Bosch num

Firm num

Name

106671-5063

INJECTION-PUMP ASSEMBLY
14CA PE6P,6PD PE

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 11.9

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 166.4 164.4 168.4

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_02

Adjusting point C

Rack position 7.2+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 16.7 15.7 17.7

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_03

Adjusting point D

Rack position 9.8

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 101.6 95.6 107.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position 9.8

Boost pressure kPa 4 4

Boost pressure mmHg 30 30

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 11.5

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position 11.9

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

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)Variable speed specification. (5)Set idle. (6)Fix the lever at the full-load position at delivery. (7)Rack limit using stop lever (8)Damper spring setting (9)Main spring setting (10)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
RT=1 TH=2.4mm
----------

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=290r/min
----------
a=21deg+-5deg b=12deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=42mm
----------
a=35deg+-3deg b=45deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the pin at R = bb
----------
aa=11.9mm bb=45mm
----------
a=35deg+-5deg b=35deg+-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:

(1) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in)(2) Bore diameter in cylinder block for the cylinder liners ... 136.00 0.03 mm (5.354 .001 in)(3) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in) (4) Spacer block.(5) Height of dowels above top surface of spacer block and cylinder block ... 8.00 0.03 mm (.315 .001 in)(6) Cylinder Liner. Make reference to the procedure for checking Cylinder Liner Projection in Testing And Adjusting Section of Service Manual Form No. SENR5108. Cylinder liner projection above the top surface of the spacer block must be ... 0.12 0.08 mm (.005 .003 in) Apply 7M7260 Liquid Gasket as required to cylinder liner shoulder and cylinder block face joint of all liners. (7) Depth plug is to be installed (from end surface of cylinder block to top of plug) ... 1.25 0.25 mm (.049 .010 in)(8) Diameter of camshaft bores ... 75.000 0.025 mm (2.9530 .0010 in)(9) Oil cooling jet assembly. Tighten bolt that holds oil cooling jet to ... 25 7 N m (18 5 1b ft)(10) Width of main bearing cap ... 175.00 0.02 mm (6.8898 .0008 in) Width in cylinder block for main bearing cap ... 175.000 0.018 mm (6.8898 .0007 in)(11) Distance from centerline of crankshaft bore to top surface of cylinder block ... 265.0 mm (10.43 in)The flatness across the top contact surface of the block must be within 0.05 mm (.002 in) for any 150 mm (5.9 in) section of the surface.(12) Distance from centerline of crankshaft to bottom surface of cylinder block ... 120.0 mm (4.72 in)(13) Main bearing cap bolts. Install as follows: Main bearing caps shall be assembled with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.Main bearing cap bolts to be lubricated on threads and washer face with SAE 30 oil or molylube. Tighten bolts to 95 5 N m (70 4 lb ft) plus 90 5° additional turn prior to machining. Tighten bolts simultaneously or tighten both bolts to 95 N m (70 lb ft) before turning the additional 90°.(14) Bore in cylinder block for seven main bearings ... 108.000 0.013 mm (4.2520 .0005 in) All main bearing bore measurements are to be made before caps are disassembled.