106672-9810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066729810

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106672-9810 1066729810

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Service parts 106672-9810 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5690

3. GOVERNOR 105487-4680

4. SUPPLY PUMP 105217-1560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105663-0380

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4222

11. Nozzle and Holder 6211-11-3301

12. Open Pre:MPa(Kqf/cm2) 24.5{250}

13. NOZZLE-HOLDER 105041-7122

14. NOZZLE 105015-6920

15. NOZZLE SET

Include in #1:

106672-9810 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106672-9810 1066729810

Zexel num

Bosch num

Firm num

Name

106672-9810

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 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

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

Overflow valve 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 1-5-3-6- 2-4

Pre-stroke mm 4.3 4.25 4.35

Beginning of injection position
Drive 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 A

Rack position 11.8+-0. 5

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 288 284 292

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_02

Adjusting point B

Rack position 11.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 268 266 270

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_03

Adjusting point F

Rack position 4+-0.5

Pump speed r/min 385 385 385

Average injection quantity mm3/st. 27 25.5 28.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 9.3

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 11.8

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

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)Deliver without the torque control spring operating. (5)Boost compensator stroke: BCL (6)Damper spring setting
----------
RT=1 TH=2.4mm BCL=2.5+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=6deg+-5deg

0000000901

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

----------
a=39.5deg+-3deg b=15deg+-5deg

Stop lever angle

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

----------
a=42.5deg+-5deg b=73deg+-5deg

Timing setting

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

----------
a=(260deg)

Information:

(1) Bore in idler gear bearing ... 28.600 0.061 mm (1.1260 .0024 in) Diameter of idler gear shaft ... 28.512 0.013 mm (1.1225 .0005 in)Clearance between bearing and shaft ... .014 to .162 mm (.0011 to .0059 in)(2) Clearance between gear and body of pump ... 0.05 to 0.66 mm (.002 to .026 in)(3) Diameter of shafts for pump ... 22.217 0.005 mm (.8747 .0002 in) Bore in bearings for shafts ... 22.286 0.051 mm (.8774 .0020 in)Clearance between shafts and bearings ... .013 to .125 mm (.0010 to .0050 in)(4) Depth that bearings are installed in pump bodies ... 1.52 0.25 mm (.060 .010 in)(5) Length of gears ... 50.808 0.025 mm (2.0003 0.0010 in) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 0.0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(6) Length of gears ... 38.070 0.025 mm (1.4988 0.0010 in) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 0.0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(7) Distance from the end of the idler shafts to gear faces ... 21.03 0.13 mm (.828 .005 in) Maximum temperature of gear when shrinking in place ... 400°C (750°F)(8) Distance from the end of the drive shaft to gear face ... 38.23 0.13 mm (1.505 0.005 in) Maximum temperature of gear when shrinking in place ... 400°C (750°F)(9) Torque for bolt holding drive gear to drive shaft ... 47 9 N m (35 7 lb ft) Install the bearings in the cover and body for the oil pump so the bearing junctions (joints) are in the position shown.(10) Distance dowel extends from body ... 4.1 0.5 mm (.16 .02 in)(11) Shaft assembly. Distance shaft assembly extends from body ... 30.50 0.25 mm (1.201 0.010 in)
Section A-A
Oil Pump Bypass Spring(12) 115-7545 Spring: Length under test force ... 22.22 mm (.875 in)Test force ... 780 N (175 lb)Free length after test ... 25.4 mm (1.00 in)Outside diameter ... 18.54 mm (.730 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.