106871-0640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710640

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0640 1068710640

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Service parts 106871-0640 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7480

3. GOVERNOR 105487-2503

4. SUPPLY PUMP 105237-1850

5. AUTOM. ADVANCE MECHANIS 105681-0161

6. COUPLING PLATE 105662-0602

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7700

11. Nozzle and Holder 16600-97070

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105031-4790

14. NOZZLE

105015-6810

15. NOZZLE SET

Include in #1:

106871-0640 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0640 1068710640

Zexel num

Bosch num

Firm num

Name

106871-0640

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 10.3

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 129.4 128.4 130.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 9 13

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Load 3/4

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Rack limit using the stop lever: R1 (4)Excess fuel setting for starting: SXL (5)Damper spring setting: DL
----------
RT=1 TH=2.1mm R1=12.4+0.2mm SXL=10.3+0.2mm DL=6.5-0.2mm
----------

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=26deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=12.4+0.2mm
----------
a=3deg+-5deg b=32deg+-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:

Start By:a. remove fuel injection lines 1. Remove bolt (1) and clamp (2) from the fuel injection nozzles to be removed.2. Install Tool (A) with the inside lip of the puller on the lower stepped diameter of the nozzle and the tip of the button in the threaded hole for bolt (1).
Do not exceed a torque of 17 N m (150 lb in) on the screw of Tool (A) during removal of the nozzle. Added force can cause the stem of the nozzle to bend or break off.
3. Tighten the screw of Tool (A) to a maximum torque of 17 N m (150 lb in) to remove fuel injection nozzle (3).4. If the fuel injection nozzle can not be removed with a maximum torque of 17 N m (150 lb in) on the screw of Tool (A), remove Tool (A).
Typical Example5. Remove the protective cap from fuel injection nozzle (3), and install Tool (B) as shown.
Hold Tool (B) so the center line of the tool is in alignment with the centerline of fuel injection nozzle (3). This will prevent distortion of the nozzle which can cause it to bend or break off during removal.
6. Remove the fuel injection nozzle with Tool (B).7. If Tool (B) was used to remove the fuel injection nozzle, replace the nozzle.8. If Tool (A) was used to remove the fuel injection nozzle, remove the carbon dam seal on the end of the nozzle.Install Fuel Injection Nozzle
1. Use Tool (C) to clean the bore for the fuel injection nozzle. Use an open end wrench or tap driver to turn Tool (C).2. Make reference to Special Instruction, Form No. SEHS7292, for the use of Tool (D). Clean the fuel injection nozzle with Tool (D). 3. Install a new seal (4) on fuel injection nozzle (3).4. Put carbon dam seal (5) on the small end of Tool (E). Expand the carbon dam seal by sliding it to the large end. Put Tool (E) against the fuel injection nozzle. Slide carbon dam seal (5) off Tool (E) on to the nozzle. Slide the carbon dam seal into position in the groove on the nozzle as shown. 5. Put fuel injection nozzle (3) in position in the cylinder head. Install clamp (2) and bolt (1) to hold the nozzle in position.End By:a. install fuel injection lines