106871-0320 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710320

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0320 1068710320

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Service parts 106871-0320 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7540

3. GOVERNOR 105488-9570

4. SUPPLY PUMP 105217-1730

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 1660097005

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-3440

15. NOZZLE SET

Include in #1:

106871-0320 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0320 1068710320

Zexel num

Bosch num

Firm num

Name

106871-0320

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 132424-0620

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 10.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 127 126 128

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.4

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 118 116 120

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 82.5 80.5 84.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

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 *

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using stop lever: R1 (at N = N1) (5)Variable speed specification. (6)Main spring setting (7)Damper spring setting
----------
RT=1 TH=3.3mm R1=12.3+-0.1mm N1=0r/min
----------

Speed control lever angle

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

----------
a=6deg+-5deg b=19deg+-5deg

0000000901

F:Full load I:Idle (1)Fix the lever at the full load position
----------

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

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Use the hole above R = cc
----------
aa=12.3+-0.1mm bb=1+0.5mm cc=32mm
----------
a=6deg+-5deg b=31.5deg+-3deg

Information:

Illustration 16 g00628694
(9) Fuel injector clamp. (10) Bolt. (11) O-ring seal.
Place the clamp (9) in the proper position. Temporarily place the jumper tube in position in order to ensure alignment of the bolt holes. Adjust the orientation of the injector until the alignment is satisfactory. Torque the bolt (10) to the following torque. Remove the jumper tube.Torque for bolt ... 47 9 N m (35 7 lb ft)
Illustration 17 g00628691
(12) O-ring seals in the injector jumper tube. (13) O-ring seals in the base of the rocker arm.
Replace the used O-ring seal (11), and the O-ring seals (12) and (13) in the jumper tube and in the rocker arm.
Illustration 18 g00628693
(14) Jumper tube. (15) Bolts. (16) Adapter. (17) Socket head screws.
Place the jumper tube (14) and the adapter (16) into position.
If the adapter was previously installed on the injector, loosen the socket head screws. Failure to loosen the socket head screws before continuing with Step 8 can result in injector failure.
Install the socket head screws (17) and the four bolts (15) finger tight.Note: The mating surfaces should be brought into complete contact and into alignment before the final torque procedure is started.
Failure to follow any of the procedures in this instruction may result in injector damage or malfunction, and possible major engine damage.
Torque Procedure
Illustration 19 g00338156
(1) Socket head screws.
Illustration 20 g00338157
(2) Two horizontal bolts. (3) Two vertical bolts.
Tighten the socket head screws (1), the two horizontal bolts (2), and the two vertical bolts (3) finger tight.
Tighten the socket head screws (1) to an initial torque of 1 .2 N m (9 2 lb in).
Tighten the horizontal bolts (2) to an initial torque of 5 3 N m (44 27 lb in).
Tighten the vertical bolts (3) to an initial torque of 5 3 N m (44 27 lb in).
Tighten the socket head screws (1) to a final torque of 12 3 N m (9 2 lb ft).
Tighten the horizontal bolts (2) to a final torque of 47 9 N m (35 7 lb ft).
Tighten the vertical bolts (3) to a final torque of 47 9 N m (35 7 lb ft).
Repeat Step 1 through Step 7 for the remainder of the injectors.
Check the fuel system for leaks by cranking the engine with the disabled injection. Then check the hydraulic pressure. Compare the pressure to the desired pressure.Cranking Without Injecting
Cranking the engine with the disabled injection may be performed by one of the following methods:
Disconnect the injector harness of the cylinders which have been reinstalled. Allow the engine to idle. Visually inspect the injector's components for high pressure oil leaks.
Activate the system "Crank Without Inject" if the option is available. On Track-Type Tractors, a "Crank Without Inject" plug can be assembled in the engine harness. On Off-Highway Trucks, the "Ground Level Shutdown" can be activated if the option is available.
When you are using the CAT ET or the ECAP, the injection may be disabled by interactive diagnostics. The engine can be left