106871-0613 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710613

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0613 1068710613

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Service parts 106871-0613 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7340

3. GOVERNOR 105487-3581

4. SUPPLY PUMP 105636-1741

5. AUTOM. ADVANCE MECHANIS 105636-1741

6. COUPLING PLATE 105662-0602

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5800

11. Nozzle and Holder 1660097068

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-6810

15. NOZZLE SET

Include in #1:

106871-0613 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0613 1068710613

Zexel num

Bosch num

Firm num

Name

106871-0613

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 10.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 127.8 126.8 128.8

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.5+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 13.5 11.5 15.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 11.7+0.2

Pump speed r/min 40 40 40

Average injection quantity mm3/st. 135 125 145

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 450--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 400

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using the stop lever: R1 (2)Excess fuel setting for starting: SXL (3)Damper spring setting: DL
----------
R1=11.7+0.2mm SXL=10.3+0.2mm DL=6-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=1deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=28deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa (2)Rack position bb
----------
aa=50mm bb=11.7+0.2mm
----------
a=27deg+-5deg b=31deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

2. Turn the crankshaft until two pistons are at bottom center.3. Remove bolts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rods from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.Install Pistons & Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. 2. Use Tool (A), and install piston (2) and the connecting rod in the cylinder liner.3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the nuts, and tighten them to a torque of 90 8 N m (67 6 lb ft). Put a mark on the nuts and cap, and tighten the nuts an extra 90 5 degrees.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.End By:a. install piston cooling tubesb. install oil pumpc. install cylinder head assemblyDisassemble & Assemble Pistons & Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with Tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with Tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See, Use Of Piston Bearing Removal And Installation Tools, Special Instructions, SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to 500° F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of Tool (C). Put a new rod pin bearing (6) on the adapter part of Tool (C). The old bearing is pushed out by Tool (C) as the new bearing is installed.7. Use Tool (C) to push the new bearing into the connecting rod until the push adapter of Tool (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in).9. Check the clearance between the ends of the piston rings. See the topic, "Pistons & Rings" in Specifications Manual, SENR6470.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint.11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston. Use Tool (B) to install