106671-5470 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715470

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-5470 1066715470

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Service parts 106671-5470 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0720

3. GOVERNOR 105407-5870

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105681-1810

6. COUPLING PLATE 105662-1200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7130

11. Nozzle and Holder 16600-96514

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}

13. NOZZLE-HOLDER 105031-4630

14. NOZZLE

105015-6340

15. NOZZLE SET

Include in #1:

106671-5470 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5470 1066715470

Zexel num

Bosch num

Firm num

Name

106671-5470

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 3.65 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 10.7

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 151 149 153

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 123 123

Boost pressure mmHg 920 920

Injection quantity adjustment_02

Adjusting point C

Rack position 10.3

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 132 129 135

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 7.1+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 29 28 30

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 10.3

Boost pressure kPa 6.7 1.4 12

Boost pressure mmHg 50 10 90

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 10.7

Boost pressure kPa 29.3 26.6 32

Boost pressure mmHg 220 200 240

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position (12)

Boost pressure kPa 109 109 109

Boost pressure mmHg 820 820 820

Timer adjustment

Pump speed r/min 750+80

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 1.5 1 2

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)Boost compensator stroke: BCL (4)Boost compensator excessive fuel lever at operation (at 0 boost pressure): L1 (5)Set idle sub-spring (6)Main spring setting
----------
K=8 BCL=(1.7)mm L1=10.7+-0.1mm
----------

Speed control lever angle

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

----------
a=2deg+-5deg b=16deg+-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 (at boost pressure = bb)
----------
aa=10.7+-0.1mm bb=0kPa(0mmHg)
----------
a=(2deg) b=(18deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)

Information:

(1) Oil cooler base bypass valve. Opening pressure ... 155 17 kPa (22.5 2.5 psi)(2) Base assembly. Tighten stud that holds filter assembly (3) to a torque of ... 68 7 N m (50 5 lb ft)(3) Filter assembly.(4) Cover. Tighten to a torque of ... 60 10 N m (44 7 lb ft)(5) Seal. Lubricate seal with lubricant being sealed.
Section A-A. Oil Filter Bypass Valve.The bypass opening pressure differential is 170 kPa (25 psi).(6) Seal.(7) Spring (8M3182): Assembled length ... 63.5 mm (2.50 in)Load at assembled length ... 36.5 N (8.92 lb)Free length after test ... 91.7 mm (3.61 in)Outside diameter ... 20.6 mm (.81 in)(8) Seal.(9) Plunger.
Section B-B. Oil Pump Bypass Valve.(10) Spring (2N6005): Assembled length ... 96.52 mm (3.800 in)Load at assembled length ... 92.52 N (20.817 lb)Operating length (min) ... 45.72 mm (1.800 in)Load at min operating length ... 257.55 N (57.949 lb)Free length after test ... 124.71 mm (4.910 in)Outside diameter ... 21.84 mm (.860 in)(11) Valve.(12) Seal.(13) Seal.
Section C-C. High Pressure Relief Valve.The relief pressure is 696 kPa (101 psi).(14) Spacer.(15) Spring (1A2170): Assembled length ... 21.43 mm (.844 in)Load at assembled length ... 198.03 13.35 N (44.500 3.000 lb)Free length after test ... 31.00 mm (1.220 in)Outside diameter ... 19.60 mm (.772 in)(16) Seal.
Oil Cooler Bypass Valve.(17) Minimum stroke ... 8.4 mm (.33 in)(18) Length of valve fully compressed ... 44.2 1 mm (1.70 .04 in)(19) Length of valve fully extended ... 52.6 1 mm (2.10 .04 in)(B) Position "B".Valve Data: Start to close temperature ... 100 to 102.8°C (212 to 217°F)Position "B" temperature activation ... 111.1°C (232°F)Position "B" bypass opening pressure differential ... 155 17 kPa (22 2 psi)Fail safe activation temperature ... 126.7°C (260°F) Unit will stroke to and remain at position "B" at failsafe activation temperature.