106871-0570 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710570

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0570 1068710570

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Service parts 106871-0570 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-9020

3. GOVERNOR 105407-3670

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:

106871-0570 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0570 1068710570

Zexel num

Bosch num

Firm num

Name

106871-0570

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 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 12.3

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 154.4 151.4 157.4

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 42.7 42.7

Boost pressure mmHg 320 320

Injection quantity adjustment_02

Adjusting point B

Rack position 12.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 165.8 163.8 167.8

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 42.7 42.7

Boost pressure mmHg 320 320

Injection quantity adjustment_03

Adjusting point C

Rack position 10.7

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 123.1 121.1 125.1

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position 6.1+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 15 13 17

Max. variation between cylinders % 0 -10 10

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 10.7

Boost pressure kPa 13.3 6.6 20

Boost pressure mmHg 100 50 150

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 12.6

Boost pressure kPa 33.3 30.6 36

Boost pressure mmHg 250 230 270

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 1100

Advance angle deg. 4.9 4.4 5.4

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 5.5 5.5 5.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Boost compensator stroke
----------
K=12 RAL=13.1+-0.1mm
----------

Speed control lever angle

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

----------
a=(11deg)+-5deg b=(22deg)+-5deg

Stop lever angle

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

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

Information:

Disconnect batteries before performance of any service work.
Start By:a. remove vibration damper
The crankshaft front seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made.
1. Make at least three holes in seal (1) with a hammer and a sharp punch.2. Use Tool (A) to remove seal (1). 3. Install Tool (C) in the seal bore.4. Install Tool (B) between Tool (C) and wear sleeve (2). Turn Tool (B) until the Tool makes a dent (crease) in wear sleeve (2). Do this in three or more places until the wear sleeve is loose.5. Remove Tools (B) and (C), and remove wear sleeve (2) from the crankshaft.Install Crankshaft Front Seal & Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the front crankshaft seal and wear sleeve with Tool (A). Use the procedures with follows:a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any 6V1541 Quick Cure Primer or 9S3265 Retaining Compound get on the lip of the seal.b. Install locator (3) and bolts (4) on the crankshaft.c. Seal (1) and wear sleeve (2) must be installed dry.
Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (1) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until the inside surface of installer (5) comes in contact with locator (3).h. Remove Tool (D) from the crankshaft seal and wear sleeve. Tool (D) will install the seal and wear sleeve to the correct depth on the crankshaft.End By:a. install vibration damper