106871-3913 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068713913

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-3913 1068713913

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Service parts 106871-3913 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7210

3. GOVERNOR 105489-0342

4. SUPPLY PUMP 105237-1410

5. AUTOM. ADVANCE MECHANIS 105681-0220

6. COUPLING PLATE 105662-0790

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7070

11. Nozzle and Holder 23600-1651

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105031-7160

14. NOZZLE

105015-4700

15. NOZZLE SET

Include in #1:

106871-3913 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-3913 1068713913

Zexel num

Bosch num

Firm num

Name

106871-3913

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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-8-6-2- 7-5-4-3

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 162 160 164

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 171.6 165.6 177.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_03

Adjusting point E

Rack position 7.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 127.5 125.5 129.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 121 121

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point G

Rack position 4.5+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.8 5.8 11.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 180 177 183

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 7.5

Boost pressure kPa 4 1.3 6.7

Boost pressure mmHg 30 10 50

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 7.9

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min (950)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 2 1.7 2.3

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 (4)Set idle at delivery (5)Damper spring setting: DL
----------
RT=0.8 TH=2.7mm DL=2.9-0.2mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)At delivery (3)Point G setting
----------
aa=46mm
----------
a=20deg+-5deg b=33deg+-3deg c=34deg+-5deg

Stop lever angle

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

----------
a=39deg+-5deg b=48.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(80deg)

Information:

Crankshaft Turns Free Exhaust Smoke Can Be Seen While Starting
Cold Outside Temperatures ... It may be necessary to use starting aids, or warm engine oil or coolant, at temperatures below 10°F (-12°C).Air in Fuel System ... See PRIMING THE FUEL SYSTEM.Low Quality Fuel ... Drain a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, drain the tank and fill with a good quality fuel. Change the fuel filter and "prime". If there is no water in the fuel, using an outside supply of fuel, prime and start the engine. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel and prime the fuel system.Fuel Injection Timing Not Correct. *Valve Adjustment Not Correct ... Check and make necessary adjustment. See VALVE LASH ADJUSTMENT.Defective Fuel Nozzle(s) ... Replace the fuel nozzles.Low Compression ... See the topic MISFIRING AND RUNNING ROUGH.Exhaust Smoke Cannot Be Seen While Starting
No Fuel in Tank ... Check fuel level visually (do not use the fuel gauge only). Be sure tank selection valve is open to the tank with fuel in it. Be sure valve in fuel line between the tanks is open.No Fuel From Fuel Injection Pump ... Loosen one or more of the fuel injection line nuts at the cylinder heads. With ignition switch on and accelerator in the fuel on position, turn the engine with the starter to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, see the following information.Prime fuel system.Check solenoid by turning on ignition switch. You must hear a sound when the plunger opens. If no sound is heard, make sure there is battery voltage at the solenoid and that the voltage is no less than 8 volts (terminal voltage while cranking). If voltage is less than 8 volts, the problem is low charge in battery or defective wiring. If voltage is 8 or more volts, loosen the cap on the tee at the fuel filter and release the fuel pressure at the solenoid. If the solenoid now works, the fuel transfer pump is holding fuel pressure at the solenoid. Clean or install a new fuel transfer pump. If solenoid does not work when pressure is released, install a new solenoid.Check for a dirty fuel filter by checking fuel pressure at the fuel filter outlet while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2) check fuel pressure at the outlet of the fuel transfer pump. If fuel pressure at the outlet of the transfer pump is more than the fuel pressure at the fuel filter outlet, install a new fuel filter.Check for a defective fuel transfer pump by checking fuel pressure at the outlet of the fuel transfer pump while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2), clean the primary fuel filter