106673-2871 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066732871

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-2871 1066732871

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Cross reference number

ZEXEL 106673-2871 1066732871

Zexel num

Bosch num

Firm num

Name

106673-2871

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 131424-4620

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 4.8 4.75 4.85

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 A

Rack position 10.9

Pump speed r/min 825 825 825

Average injection quantity mm3/st. 142.5 139.5 145.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

Injection quantity adjustment_02

Adjusting point B

Rack position 6.5+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 19 16.4 21.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 11.65

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 161 155 167

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

Injection quantity adjustment_04

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 110 150

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position (10.6)

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position (11.8)

Boost pressure kPa 34.7 28 41.4

Boost pressure mmHg 260 210 310

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 850

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

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)RACK LIMIT (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2 (6)Main spring setting (7)Set idle sub-spring
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K=11 N1=825r/min N2=625r/min
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Speed control lever angle

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

----------
a=0deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Stopper bolt setting
----------
aa=0r/min bb=1-0.2mm
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a=35deg+-5deg b=70deg+-5deg

Timing setting

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

----------
a=(7deg)

Information:

Installation of Nozzles, Ether Supply Tubes and Connectors
1. If the machine does not already have an ether aid starting system, remove the plugs from turbocharger outlet adapters on the engine. 2. Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (2) where each plug was removed. If machine was equipped with an ether aid starting system. Discard old nozzles and install new nozzles.3. When installing each nozzle assembly (2), the indicator mark at location (J) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).
Top View
Side View DO NOT overtighten tube assembly fittings. Over tightening can cause damage to tubing.4. Install 8X0912 Tube (9) in the front nozzle and 8W8174 Tube (7) in the rear nozzle as shown. Connect tubes (7) and (9) to 8C9006 Tee (8) using two 5P6314 Sleeves and 5P6313 Nuts.5. Put 8W8172 Tube (5) in position along the cylinder block and connect it to 8C9006 Tee (8) as shown using 5P6314 Sleeve and 5P6313 Nut.6. Connect one end of 8W8171 Tube (10) to elbow (11) on the bottom of the shuttle valve using a 5P6313 Nut and 5P6314 Sleeve. Fasten the tube to the frame cross tube using 6V2686 Clip (6) as shown.7. Connect one end of 7N0140 Tube Assembly (4) to the end of 8W8171 Tube (10) and connect the other end to the free end of 8W8172 Tube (5).8. Fasten the ether tubing assemblies, using three 6V2686 Clips (3) with existing bolts, on engine block and right regulator housing as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "OO". This in an indication that there are no faults.If the display does not read "OO", refer to the Service Manual for a troubleshooting procedure of the system. 3. Remove protective caps (1) and (3) from 9X7137 Ether Solenoid Valves (2) and (4). Install a new 9X7138 Filter Assembly in each solenoid valve inlet.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder on ether solenoid valve (2). The ether valve assembly at left location (C) is referred to as Ether Assembly No. 1. The ether valve assembly at right location (D) is referred to as Ether Assembly No. 2.Make sure that the dash mounted ETHER OUT warning lamp No. 1 and the ETHER OUT warning LED on the ECU are OFF. Repeat this procedure for installation of