106871-5000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5000 1068715000

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Cross reference number

ZEXEL 106871-5000 1068715000

Zexel num

Bosch num

Firm num

Name

106871-5000

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 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)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting (4)Variable speed specification: idling adjustment (5)Fix the lever at the full-load position at delivery. (6)Main spring setting
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SXL=10.3+-0.1mm
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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.)
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aa=290r/min
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a=(11deg)+-5deg b=5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=64.3mm
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a=18.5deg+-5deg b=23.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
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----------
a=12deg+-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:

2. Disconnect the fuel injection lines (2) from pump housing. Put plugs or caps in all lines and openings.3. Remove the three bolts that hold the fuel filter (3) to the aftercooler housing.4. Disconnect the sensing line (1) for the fuel ratio control from the aftercooler housing. 5. Disconnect the oil supply line (4) from the turbocharger.6. Remove the two water lines (5). 7. Disconnect the water outlet line (6) for the air compressor from the cylinder head.8. Remove the bolts (7) that fasten the cylinder head to the cylinder block. 9. Install 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and remove the cylinder head assembly. Weight of cylinder head assembly is 575 lb. (260 kg). Be sure to install a new gasket between the spacer plate and the cylinder block before installing the cylinder head assembly. See REMOVE and INSTALL SPACER PLATE in DISASSEMBLY AND ASSEMBLY.Install Cylinder Head Assembly
1. Clean the top surface of spacer plate and the surface it is in contact with on the cylinder head.2. Install the cylinder head gasket, water seals, and gasket on timing gear cover. 3. Install the 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and put the cylinder head assembly into position on the engine. Make sure the gear (1) in cylinder head is engaged with drive gear (2). 4. Put 9M3710 Anti-Seize Compound on the threads of the bolts for cylinder head. Install the bolts and washers. Tighten the bolts as follows: 1 -Tighten all bolts in number order to 135 lb.ft. (18.7 mkg).2 -Tighten all bolts in number order to 185 5 lb.ft. (25.6 0.7 mkg).3 -Tighten all bolts using hand torque only to 185 5 lb.ft. (25.6 0.7 mkg). 5. Install the two water lines (4).6. Connect the oil supply line (3) to the turbocharger.7. Connect the water outlet line (5) for the air compressor to the cylinder head. 8. Connect the sensing line (6) for the fuel ratio control to the aftercooler housing.9. Put the fuel filter in position, and install the three bolts.10. Remove the plugs and fuel injection lines and pumps. Connect the fuel injection lines (7) to the pumps. Tighten the nuts on fuel lines to 30 5 lb.ft. (4.1 0.7 mkg).11. Fill the cooling system with coolant.end by: a) install camshaft housingb) install fan drive