106673-7640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737640

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7640 1066737640

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Cross reference number

ZEXEL 106673-7640 1066737640

Zexel num

Bosch num

Firm num

Name

106673-7640

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 9.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 116 113 119

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12.5 9.9 15.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 125 145

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 0

Advance angle deg. 2.5 2 3

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2 3

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Torque spring does not operate. (4)RACK LIMIT (5)Main spring setting (6)Set idle sub-spring
----------
K=10
----------

Speed control lever angle

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

----------
a=(23deg)+-5deg b=(7deg)+-5deg

Stop lever angle

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

----------
a=19deg+-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=12deg
----------
a=(6deg)

Information:

(1) Remove former fuel injection lines (1), the clamps and through-the-cover fuel line adapters (2) from the engine; these parts will not be needed again. Install 8M4437 Seals on twelve 1W6777 Adapters (3). Put engine oil on the seals and install the adapters in valve cover base assemblies (4) where adapters (2) were removed. Fasten the adapters to bases (4) with two 5N5365 Locks on each and the former nuts. Connect former fuel lines (5) to adapters (3) and the former fuel nozzle adapters. (2) Install a 2W2500 Washer (7) and a 6V6579 Seal (8) on each adapter (3). Install a 5P9267 Seal on each injector pump; put diesel fuel on the seals before installation. Loosely install fuel injection line assemblies: number "6" (9), number "12" (10), number "4" (11), number "2" (12), number "10" (13) and number "8" (14) on the right side of the engine between the fuel injection pumps and adapters (3). See the above chart for the correct part number of the fuel lines. Remove two bolts and install 5N5370 Bracket (15) and 5N5374 Clamp (16) where the bolts were removed. Fasten the fuel injection lines to bracket (15) with two 5N5369 Dampers, a 5N5371 Clamp and two 2W7884 Bolt Assemblies. Fasten the fuel injection lines to clamp (16) with two 5N5373 Dampers, a 5N5372 Clamp and two 2W7884 Bolts. Use 5N5957 and 5N5958 Clamps, two 5N5956 Dampers and a 2W7884 Bolt Assembly to fasten the fuel lines together at (A). Use 5N5376 and 5N5377 Clamps, two 5N5375 Dampers and three 2W7884 Bolt Assemblies to fasten the fuel lines together at (B). Tighten the bolt assemblies to 10 N m (7 lb.ft.) torque. Tighten nuts (17) on each end of the fuel injection lines to 40 7 N m (35 5 lb.ft.) torque, then tighten nuts (18).(3) Loosely install fuel injection line assemblies; number "11" (19), number "3" (20), number "7" (21), number "9" (22), number "5" (23) and number "1" (24) on the left side of the engine between adapters (3) and the fuel injection pump as shown. Remove a bolt and install 5N5370 Bracket (25) where the bolt was removed. Fasten the fuel lines to bracket (25) with two 5N5369 Dampers, a 5N5371 Clamp and two 2W7884 Bolts. On engines equipped with aftercooler, fasten 5N5379 Plate (26) to an existing bolt on the aftercooler. Fasten the fuel injection lines to plate (26) with two 5N5378 Dampers, a 5N5374 Clamp and two 2W7884 Bolt Assemblies. Use two 5N5376 and 5N5377 Clamps, four 5N5375 Dampers and four 2W7884 Bolt Assemblies to fasten the fuel lines together at locations (C). If the engine does not have an aftercooler, use 5N5957 and 5N5958 Clamps, two 5N5956 Dampers and a 2W7884 Bolt Assembly to fasten the fuel injection lines together at (D). Tighten the fuel lines as shown in step 2.2W5100 Fuel Lines Drain Group
(1) Install a 9L8496 Tee (1) in each adapter (2). Connect tees (1) together with ten 5N5940 Tube Assemblies (3).