106671-9820 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066719820

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-9820 1066719820

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Service parts 106671-9820 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-1510

3. GOVERNOR 105923-4100

4. SUPPLY PUMP 105237-5180

5. AUTOM. ADVANCE MECHANIS 105681-4400

6. COUPLING PLATE 105662-1420

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

106671-9820 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-9820 1066719820

Zexel num

Bosch num

Firm num

Name

106671-9820

DPICO

INJECTION-PUMP ASSEMBLY
6D22 * Q

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131425-0220

Overflow valve opening pressure kPa 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 129 125.8 132.2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 570 570 570

Each cylinder's injection qty mm3/st. 15 13 17

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 128 130

Basic *

Fixing the lever *

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1.5 1 2

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 3.5 3 4

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 4 3.5 4.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Damper spring setting: DL
----------
T1=AG11 DL=7.9-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=0deg+-5deg b=(33deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=45mm bb=1100r/min cc=3.5+-0.3mm
----------
a=29.5deg+-5deg b=40deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=475r/min Ra=7.6+-0.1mm
----------

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=11deg
----------
a=(5deg)

Information:

Illustration 3 g06519715
DOC brackets
Illustration 4 g06519717
DOC
Connect the welding ground cable directly to the DOC brackets or the DOC that will be welded. Place the ground cable as close as possible to the weld. This location will reduce the possibility of welding current damage bearings, hydraulic components, electrical components, and ground straps.Note: If electrical components are used as a ground for the welder, current flow from the welder could severely damage the component. Current flow from the welder could also severely damage electrical components that are located between the welder ground and the weld.
Illustration 5 g06519270
Weld blanket
Illustration 6 g06519272
Use a weld blanket draped over the engine to protect the engine from weld splatter. Likely need 2 or 3 blankets to cover between DOCs and the entire engine from splatter.
Illustration 7 g06519274
Illustration 8 g06519277
(1) 536-5400 Plate
Clean the top surface in the two locations where plates (1) will be welded in place with either a wire wheel or a flap disk.Note: Failure to clean the weld area could result in poor weld quality.
Illustration 9 g06519323
(D1) 6 2 mm (0.236 0.079 inch)
Illustration 10 g06519297
(D1) 6 2 mm (0.236 0.079 inch)
(D2) 43 3 mm (1.693 0.118 inch)
Illustration 11 g06519348
(D2) 43 3 mm (1.693 0.118 inch)
Set the plates on the top side of the housing and line up perpendicular to the front face. Position the plates to dimension (D1) from the front edge of the top plate.
Position the plates to dimension (D2) from the far edge of the rounded plate. There is a chamfer and fillet weld that will make measurements less precise. Use a tape measure to position.Note: Etching marks may also be present on the top of the unit and can be used for further positional guidance.
Illustration 12 g06519373
(W1) Tack weld
With the plates in place, add tack welds (W1) to the plates shown in Illustration 12. Use 308L weld wire.
Illustration 13 g06519408
(W2) 50 to 100 mm (1.969 to 3.937 inch)
Skip fillet weld (W2) down the side of each plate and then weld at the ends of each plates. Use 308L weld wire.
Illustration 14 g06519430
Finished product
Verify the weld quality and look for the following:
Cracks
Porosity
Inclusions
Convexity/Excess Weld Material
Concavity/Under Fill
Excess Penetration
Lack of Penetration
Fillet Weld - Undersize
Lack of Fusion
Undercut
Toe Radius
Overlap
Poor Restarts/Tie-ins
Cleaning/Grinding
Spatter/Arc Strike/Wire Stub
Illustration 15 g06519435
Mark the new plates with "THIS SIDE UP".Note: Make sure that the text is visible and stands out on the DOC.