106673-7601 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737601

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7601 1066737601

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Cross reference number

ZEXEL 106673-7601 1066737601

Zexel num

Bosch num

Firm num

Name

106673-7601

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 8.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77.5 74.5 80.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 6.9 12.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 90 110

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 2.5 2 3

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)RACK LIMIT (4)The torque control spring must does not have a set force. (5)Set idle sub-spring
----------
K=14
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=22deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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----------
a=43.5deg+-5deg b=53deg+-5deg

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=13deg
----------
a=(7deg)

Information:

Before any service work is to be done on the fuel system, the outer surface of the injection pump housing must be clean.
Illustrations show fuel injection pump housing and governor removed from engines. Service work can be done with it installed on engine. 1. Remove the flange (1) and flange assembly (2) from the cover (3).2. Remove the cover from the pump housing by removing seven bolts. 3. Remove the solenoid (4) from the cover.4. Remove cover (6).5. Remove two bolts (5) that hold the cover to the shutoff housing. 6. Remove the cover from the shutoff housing (7). 7. Remove the lever (10) from the shaft (11).8. Remove the shaft (9) from the shutoff housing.9. Remove the lever (8) from the shaft (11).10. Remove the shaft (11) from the shutoff housing.11. Remove the seal (12) from the shutoff housing.Install Shutoff Housing
1. Put 5S1454 Sealing Compound on the outside diameter of the seal and install the seal (1) with tooling (A) in the shutoff housing with the lip toward the outside. The outer face of the seal must be .039 in. (1.0 mm) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Install the shaft (3) in the shutoff housing.3. Install the lever (5) on the shaft (3).4. Install shaft (2) in the shutoff housing.5. Install the lever (4) on shaft (3). 6. Put the cover (6) in position on the shutoff housing and install two bolts that hold the cover to the housing. 7. Install the cover (8).8. Install the solenoid (7) on the cover.9. Install the cover (6) on the pump housing.10. Install the flange assembly and the flange on the cover.