106871-5130 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715130

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5130 1068715130

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Cross reference number

ZEXEL 106871-5130 1068715130

Zexel num

Bosch num

Firm num

Name

106871-5130

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 3.65 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 10

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 123 122 124

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.9+-0.5

Pump speed r/min 280 280 280

Average injection quantity mm3/st. 11.5 9.5 13.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 125 165

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 500--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 450

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3.5 3 4

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 (N = N1) (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=10.2+-0.1mm N1=400r/min
----------

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=13.5deg+-5deg b=5deg+-5deg

0000000901

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

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Drive side
----------
aa=28mm
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a=64deg+-5deg b=20deg+-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:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Some of the 3408E engines and 3412E engines in the above listed machines may experience hard starting or low power due to oil that is leaking past the poppet valve in the injector. The oil leakage is caused by the operating conditions at either low idle or high idle. Excessive oil leakage can reduce actuation pressure to the fuel injector. This may prevent fuel injection.Solution
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Follow the proper troubleshooting procedure for the correct engine. If the problem is not located and the symptoms that are listed above continue, remove the engine valve covers. Electrically disable the injectors. Crank the engine. Watch the spill ports of the injector for oil leakage. A small amount of oil leakage is acceptable. A continuous stream of oil may mean leakage from the poppet valve. Excessive leakage from the poppet valve may prevent fuel injection.Note: Normal oil pressure during cranking should be 5 MPa (725 psi). Oil pressure below 5 MPa (725 psi) may indicate excessive oil leakage in injectors. Do not replace the oil pump. Service personnel should replace the injectors that have a continuous flow of oil from the oil ports. Injectors that have a continuous flow of oil and injectors that are within the guidelines of warranty can be returned. Injectors that do not have a continuous flow of oil should not be replaced. Injectors that do not have a continuous flow of oil should not be returned.Note: For additional information on the operation of Hydraulic Electronic Unit Injectors HEUI, refer to CD, RENR1390.
Illustration 1 g01308874
(1) Oil drain portThe oil drain ports are located underneath the solenoid. This will direct the oil flow downward. Some oil may also leak from the rectangular slots at the side of the solenoid. Excess oil leakage will still be visible on the cylinder head.