106671-5650 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715650

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-5650 1066715650

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Service parts 106671-5650 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0260

3. GOVERNOR 105952-2000

4. SUPPLY PUMP 105237-4210

5. AUTOM. ADVANCE MECHANIS 105691-4010

6. COUPLING PLATE 105663-0630

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7670

11. Nozzle and Holder 16600-96611

12. Open Pre:MPa(Kqf/cm2) 18.6{190}/22.6{230}

13. NOZZLE-HOLDER 105041-4190

14. NOZZLE

15. NOZZLE SET 105019-0471

Include in #1:

106671-5650 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5650 1066715650

Zexel num

Bosch num

Firm num

Name

106671-5650

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 131425-0120

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

RED3 control unit part number 407910-3 960

RED3 rack sensor specifications mm 19

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 3.87 3.93

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

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

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

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

Injection quantity adjustment

Rack position (14.3)

Vist V 1.71 1.71 1.71

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 169 168 170

Max. variation between cylinders % 0 -4 4

Basic *

Injection quantity adjustment_02

Rack position (9)

Vist V 2.5 2.4 2.6

Pump speed r/min 380 380 380

Average injection quantity mm3/st. 16.6 15.6 17.6

Max. variation between cylinders % 0 -10 10

Test data Ex:

Governor adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N4=800r/min C4=(8deg) t1=2--sec. t2=2--sec.
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N1=400r/min N2=1000++r/min N3=1250r/min C1=8+-0.3deg C2=4++deg C3=4--deg P1=0kPa(0kgf/cm2) P2=196kPa(2kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=20mm bb=1mm
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a=20deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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a=(30deg)

Stop lever angle

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:

Start By:a. remove flywheelb. remove crankshaft rear seal 1. Install Tool (A) in the bore for the crankshaft rear seal as shown.2. Install Tool (B) between Tool (A) and the crankshaft wear sleeve. Turn Tool (B) until the edge of the tool makes a crease in the crankshaft wear sleeve. Repeat this in two more locations around the crankshaft wear sleeve until it is loose.3. Remove Tool (A) and the crankshaft wear sleeve from the end of the crankshaft.Install Salvaged Crankshaft Wear Sleeve
1. Be sure the flange of the crankshaft is thoroughly clean prior to installing the crankshaft wear sleeve.
The crankshaft wear sleeve has a taper on the outside diameter. It must be installed correctly on the crankshaft.
2. Put crankshaft wear sleeve (1) in position on the 1U7597 Sleeve Ring [part of Tool (A)]. Be sure the taper on the outside diameter of the wear sleeve is facing away from the sleeve ring as shown.3. Fasten the 1U7595 Locator Assembly [part of Tool (A)] to the rear of the crankshaft. 4. Position crankshaft wear sleeve (1), with the sleeve ring, over the locator assembly as shown.5. Install the 1U7594 Installer [part of Tool (A)] over the locator assembly. Tighten the nut assembly of Tool (A) to push the crankshaft wear sleeve into position on the crankshaft.6. Remove the installer and the sleeve ring from the locator assembly. Turn the sleeve ring around, and install it and the installer back on the locator assembly. Tighten the nut assembly of Tool (A) to complete the installation of the crankshaft wear sleeve.End By:a. install crankshaft rear sealb install flywheel