106871-5120 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715120

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5120 1068715120

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Service parts 106871-5120 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5430

3. GOVERNOR 105489-4160

4. SUPPLY PUMP 105237-6020

5. AUTOM. ADVANCE MECHANIS 105683-0170

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7040

11. Nozzle and Holder 16600-97078

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

13. NOZZLE-HOLDER 105041-4020

14. NOZZLE 105015-9240

15. NOZZLE SET

Include in #1:

106871-5120 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5120 1068715120

Zexel num

Bosch num

Firm num

Name

106871-5120

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 132424-0620

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 3.9 3.85 3.95

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 10.7

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 144 143 145

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point E

Rack position 6.2+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 9.5 7.5 11.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 160

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min (780)

Advance angle deg. 1 0.7 1.3

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1000

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 6 5.7 6.3

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
----------
SXL=11.2+-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=7.5deg+-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=29deg+-3deg

Stop lever angle

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

Parts Location
Illustration 2 g01533736
(1) 8L-5423 Spacer (2) 294-9630 Diesel Particulate Filter Group (3) 294-9631 Clamp Assembly (4) 294-9632 Support Assembly (5) 296-0080 Tube (6) 7X-7729 Washer (7) 8T-4133 Nut (8) 8T-4182 Bolt (9) 8T-6466 Bolt Installation Procedure
Read and understand the instructions in Special Instruction, REHS1807, "Installation Guide for Particulate Trap Exhaust Filters".The installation procedure that follows is specific for the listed machines.Diesel Particulate Filter Installation
Illustration 3 g01473913
(4) 294-9632 Support Assembly (14) 241-9265 Muffler Clamp
Illustration 4 g01457904
(1) 8L-5423 Spacer (6) 7X-7729 Washer (8) 8T-4182 Bolt
Remove the existing muffler. Keep the muffler clamp. The muffler clamp will be reused in Step 7.Note: A new 241-9265 Muffler Clamp (14) may be needed if the existing muffler clamp cannot be reused.
Install 294-9632 Support Assembly (4) by using three 8T-4182 Bolts (8), three 7X-7729 Washers (6), and three 8L-5423 Spacers (1). Refer to Illustrations 3 and 4.
Illustration 5 g01457901
(5) 296-0080 Tube
Replace the existing inlet tube with a new 296-0080 Tube (5). Refer to Illustration 5.
Illustration 6 g01457906
(1) 8L-5423 Spacer (3) 294-9631 Clamp Assembly (Lower half) (4) 294-9632 Support Assembly (6) 7X-7729 Washer (9) 8T-6466 Bolt
Remove the two bolts, two hard washers, two lock washers, and two nuts from 294-9631 Clamp Assembly (3). Keep these parts together with the upper half of the clamp assembly. These parts will be reinstalled in Step 8.
Align the mounting holes in the lower half of 294-9631 Clamp Assembly (3) with the mounting holes in 294-9632 Support Assembly (4). Secure by using two 8T-6466 Bolts (9), two 7X-7729 Washers (6), and two 8L-5423 Spacers (1). Refer to Illustration 6.
Illustration 7 g01457907
(1) 8L-5423 Spacer (2) 294-9630 Diesel Particulate Filter Group (6) 7X-7729 Washer (7) 8T-4133 Nut (9) 8T-6466 Bolt
Align the mounting holes in the support leg of 294-9630 Diesel Particulate Filter Group (2) with the mounting holes in the engine block. Secure by using two 8T-6466 Bolts (9), two 8L-5423 Spacers (1), two 8T-4133 Nuts (7), and four 7X-7729 Washers (6). The weight of the diesel particulate filter group is approximately 34 kg (75 lb). Refer to Illustration 7.
Illustration 8 g01457909
(A) Inlet tube (3) 294-9631 Clamp Assembly (Upper half) (3a) Bolt (3b) Hard washer (3c) Lockwasher (3d) Nut
Secure inlet tube (A) with the muffler clamp that was previously removed in Step 1 or use a new 241-9265 Muffler Clamp (14) if the existing muffler clamp cannot be reused. Refer to Illustration 8.
Align the mounting holes in the upper half of 294-9631 Clamp Assembly (3) with the mounting holes in the lower half of the clamp assembly. Secure by reinstalling two bolts (3a), two hard washers (3b), two lockwashers (3c), and two nuts (3d) that were previously removed in Step 4. Refer to