106871-0970 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068710970

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-0970 1068710970

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Buy INJECTION-PUMP ASSEMBLY 106871-0970 zexel genuine, new aftermarket engine parts with delivery

Service parts 106871-0970 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5250

3. GOVERNOR 105489-3620

4. SUPPLY PUMP 105237-6020

5. AUTOM. ADVANCE MECHANIS 105683-0100

6. COUPLING PLATE 105663-0770

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}

13. NOZZLE-HOLDER

14. NOZZLE

105015-6810

15. NOZZLE SET

Include in #1:

106871-0970 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-0970 1068710970

Zexel num

Bosch num

Firm num

Name

106871-0970

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 134424-4220

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 4.7 4.65 4.75

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 11.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 143.7 142.7 144.7

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.3+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 13 11 15

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 142 142

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1000

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 6 5.5 6.5

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)Supplied with torque spring not set. (5)Excess fuel setting for starting: SXL (6)Damper spring setting (7)Variable speed specification: idling adjustment (8)Fix the lever at the full-load position at delivery. (9)Main spring setting
----------
RT=1 TH=2.5mm SXL=11.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=12deg+-5deg b=7deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=28.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the pin at R = aa
----------
aa=28mm
----------
a=10.5deg+-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:

To prevent possible personal injury, care must be taken when pin (17) is removed. The spring and plunger behind pin (17) are under spring force.
11. Remove pin (17), the spring and the plunger from the control lever.12. Remove band assembly (18) from the lever assembly. 13. Remove two seals (20) and bearing (19) from the governor housing. 14. Remove spring (22) from governor bolt (21).15. Remove seat (23) from riser (24).16. Remove the dowel from riser (24).17. Remove riser (24) and governor bolt (21) as a unit from governor plate (25).18. Remove governor bolt (21) from riser (24). 19. Remove spring (27) and washer (26) from the sleeve.20. Remove sleeve (28) from the servo piston valve. 21. Remove ring (32), large race (31), bearing (29) and small race (30) from sleeve (28). 22. Remove lock (34) from flyweights (33).23. Remove flyweight (33) from the governor plate. 24. Turn the governor plate over, and bend locks (36) down. Remove bolts (37), bracket (35) and the servo piston assembly from the governor plate. 25. Remove dowel (43), lever (44) and the servo piston assembly from bracket (35).26. Remove pin (42) and piston (38) from sleeve (40).27. Remove valve (39) from piston (38).28. Remove O-ring seal (41) from sleeve (40). 29. Tap lightly on cylinder (45) to remove it from the governor plate. 30. Remove O-ring seals (46) from cylinder (45). 31. Use Tool (A) to remove retaining ring (47) from the gear assembly. 32. Remove ring (51), spring (50), drive assembly (48) and ring (49) from gear assembly (52). 33. Use Tool (B) to remove ring (53) from drive gear assembly (52). Remove drive gear assembly (52) from the governor plate. 34. If dowel replacement is needed remove dowels (55), (56) and (57) from the governor plate.35. Remove bearing (54) from the governor plate.Assemble Governor
1. If a replacement of the dowels in the governor plate is necessary, see the illustration for correct installation dimensions. 2. Install bearing (1) for drive gear (2) in governor plate (3) with Tooling (A) until it is 0.51 0.25 mm (.020 .010 in) below the top surface of the governor plate. 3. Put clean engine oil on the inside diameter of bearing (1). Install drive gear (2) in governor plate (3). 4. Turn governor plate (3) over, and install snap ring (4) that holds drive gear (2) in place. 5. Install O-ring seals (6) on cylinder (5). 6. Put clean engine oil on the O-ring seals on cylinder (5). Install cylinder (5) in the governor plate with the notch in the cylinder in alignment with the bolt hole in the governor plate as shown.7. Install the O-ring seal on sleeve (9).8. Put clean engine oil on piston (7), sleeve (9) and valve (8). Install sleeve (9) on piston (7) and valve (8) in piston (7) as shown.9. Install the servo piston assembly in cylinder (5). Valve (8), sleeve (9) and piston (7) are parts of the servo piston assembly. 10. Put lever (11)