106871-0171 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710171

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0171 1068710171

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Service parts 106871-0171 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7540

3. GOVERNOR 105407-1981

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105636-5050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-4760

11. Nozzle and Holder 16600-97005

12. Open Pre:MPa(Kqf/cm2) 22.6{230}

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-3440

15. NOZZLE SET

Include in #1:

106871-0171 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0171 1068710171

Zexel num

Bosch num

Firm num

Name

106871-0171

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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-8-7-5- 4-3-6-2

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 11.3

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 139.2 138.2 140.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_02

Adjusting point B

Rack position 9.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 109.1 107.1 111.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 12.8 11.7 13.9

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 500 500 500

Rack position 9.9

Boost pressure kPa 16 9.3 22.7

Boost pressure mmHg 120 70 170

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 11.3

Boost pressure kPa 30 28.7 31.3

Boost pressure mmHg 225 215 235

Timer adjustment

Pump speed r/min 300+100

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 3.4 2.9 3.9

Timer adjustment_04

Pump speed r/min 1250+50

Advance angle deg. 5.5 5 6

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: RAL (4)Damper spring setting: DL
----------
K=17 RAL=12.3+-0.1mm DL=6-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=18deg+-5deg b=32deg+-3deg c=29deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=16.5deg+-5deg b=50deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=6mm
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a1=A a2=B a3=C a4=D r1=700r/min r2=750r/min r3=700r/min r4=700r/min Q1=- Q2=139.2+-1mm3/st Q3=- Q4=102.6+-1mm3/st c1=+-2.5% c2=+-2.5% c3=+-2.5% c4=+-2.5% a5=24 a6=23 a7=22 a8=21 a9=20 a10=19 a11=18 a12=17 a13=- a14=- a15=- r5=1200r/min r6=1150r/min r7=1100r/min r8=1050r/min r9=1000r/min r10=950r/min r11=900r/min r12=850r/min r13=- r14=- r15=- R5=1290+-30r/min R6=1235+-28r/min R7=1180+-27r/min R8=1130+-26r/min R9=1075+-25r/min R10=1020+-23r/min R11=965+-22r/min R12=915+-22r/min R13=- R14=- R15=-

Information:

307-OR to S Terminal of Key Switch, 308-YL to R Terminal of Key Switch, 105-BR to B Terminal of Key Switch,7. Connect additional leads to the key switch by loosening the screws and placing 307-OR, 308-YL and 105-BR leads under the screws and tighten. Make sure to match existing wire codes and color.8. Clip EPTC-II data link extension of EUI Retro harness (used for EPTC II) with 3T3048 clip assembly. 9. Remove existing console panel located towards rear of console directly above transmission control box (EPTC).
1053652 Panel Group. 1. 1052038 Plate. 2. 1052484 Film. 3. 6T6066 Switch Assembly. 4. Two 6T6329 Bezel. 5. Four 5P7590 Bolt. 6. 6T3990 Switch Assembly. 7. Four 3E8043 Screw. 8. 8C6354 Cap. 9. Four 5P1075 Washer. 10. 7T0493 Plug. 11. Four 6V8801 Nut. 12. Two 3T0304 Base. 13. Two 7N1996 Lamp. 14. Two 6T7058 Lens. 15. Two 6T2774 Clip. 16. Four 6B4540 Nut. 17. Four 6D3033 Screw. 18. Four 6V9497 Washer. 19. 1049543 Harness Assembly. 20. 1052045 Panel. 1 10. Assemble the 1053652 Panel Group as shown in the illustrations above.
1049543 Harness Assembly11. Connect the harness and individual wires as shown. Clip 1049543 Harness to the panel with 8M2773 Clip.12. Connect the EUI Retro harness to 1049543 Harness Assembly. Clip the connection with a 3T3046 Clip Assembly. Position the panel group back in place on the console with the existing hardware.Cab EUI Retrofit Harness (Front of Cab)
A major portion of the EUI Retro harness will extend through the tunnel to the front of the cab where connections must be made to the:* Overspeed warning light* Throttle pedal* Warning hornOverspeed warning light
Route the front portion of the Retro Harness through the tunnel under the cab. The plate under the cab may be removed for easier access.All trucks after 9ZC133 were equipped with an engine overspeed control module located in the front of the cab. This function is now handled by the EUI-Electronic Control Module. Part of this old system (8W0584 Wiring Group-Cab) must be disconnected and removed.Remove the following items.
8W0584 Wiring Group. 1. 8W7193 Harness Assembly. 2. 7T3821 Control Group. 3. 9D3721 Switch. 4. Two 7N8419 Terminals. 5. Three 4M5282 Bolts. 6. Three 5P4115 Washers.Overspeed Warning Group
All trucks with PINS 9ZC1 thru 9ZC132, a Special Instruction SEHS8863 Installation of Off-Highway Truck Engine Overspeed Warning Indicator Group was available to update these trucks with the stand alone engine overspeed system.This Special Instruction should be used for all trucks within this PIN range.* Trucks that was not retro-fitted with engine overspeed.* Trucks that had been retro-fitted with Special Instruction SEHS8863.Trucks That Was Not Retro-fitted
Install just the items given in the following chart on these trucks. The 12 items in the chart above must be installed to complete the EUI Retro-fit on those trucks that had no overspeed warning installed. The following Steps were taken from Special Instruction SEHS8863. The following Steps are similar to the Steps in SEHS8863. Do only those things that are spelled out in these 12 Steps, which were taken from SEHS8863.1. Disconnect