106871-0900 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710900

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0900 1068710900

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Service parts 106871-0900 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7710

3. GOVERNOR 105487-5180

4. SUPPLY PUMP 105237-1870

5. AUTOM. ADVANCE MECHANIS 105681-0710

6. COUPLING PLATE 105662-1240

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7040

11. Nozzle and Holder 16600-97073

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

13. NOZZLE-HOLDER 105030-4190

14. NOZZLE

105015-8580

15. NOZZLE SET

Include in #1:

106871-0900 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0900 1068710900

Zexel num

Bosch num

Firm num

Name

106871-0900

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 9.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 115.7 114.7 116.7

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 120 116 124

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 6.7+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 10.4 8.4 12.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 155

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

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)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting
----------
RT=1 TH=1.8mm SXL=10.3+-0.1mm N1=410r/min
----------

Speed control lever angle

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

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

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=46mm
----------
a=24deg+-3deg b=33deg+-5deg

Stop lever angle

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

----------
a=20deg+-5deg b=64deg+-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 the plug, and move the race until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.
To prevent possible personal injury carefully follow the steps below.
2. Put Tool (B), except for the 8T5287 Wrench, in position on the fuel pump housing as shown. Lower the handle to center the adjusting screw with the fuel line seat. With the handle down in the locked position, the adjusting screw must just be in contact with fuel line seat (1). If force is needed to lower the handle or there is a gap, remove the tooling, and make an adjustment to the screw.3. Loosen bushing (2) 1/4 of a turn.4. Put Tool (B) in position on the pump housing with the handle down in the locked position as shown.5. Remove bushing (2) from the pump housing.6. Carefully and slowly lift the handle to release the spring force. Remove the tooling. 7. Install Tool (C) on fuel pump (4) as shown.8. Remove seal (3) and fuel pump (4) from the fuel pump housing. 9. Remove spacers (5) from the pump housing. There must be a pump installed on either side of the pump to be removed to install Tool (B). If there is no pump, take a pump already removed, and remove the spring so there will be no spring force, and install it in the pump housing. See Install Fuel Pump. Spacers (5) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.Install Fuel Injection Pumps
1. Install spacers (5) in the fuel pump housing.2. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Install a fuel pump without its spring so that Tool (B) can be installed. See Step 5 for correct fuel pump installation. 4. Install Tool (C) on the bonnet of the fuel pump as shown.5. Install the fuel pump in the pump housing with the saw cut (slot) (9) in the gear in alignment with small pin (6) in the lifter assembly and groove (8) in the barrel in alignment with large pin (7) in the pump housing. 6. Install the seal and bushing (2) on the fuel pump.7. Put Tool (B) in position on the fuel pump housing as shown.8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do not try to use force on it. Remove and install the tooling and the fuel pump again.9. Make sure the seal is in its correct position, and start to tighten bushing (2). Remove the tooling, and tighten the bushing to a torque of 260 15 N m (190