106871-5160 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715160

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5160 1068715160

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Service parts 106871-5160 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5451

3. GOVERNOR 105489-4150

4. SUPPLY PUMP 105237-6020

5. AUTOM. ADVANCE MECHANIS 105683-0180

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7070

11. Nozzle and Holder 16600-97079

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

13. NOZZLE-HOLDER 105041-4020

14. NOZZLE

15. NOZZLE SET 105019-0250

Include in #1:

106871-5160 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5160 1068715160

Zexel num

Bosch num

Firm num

Name

106871-5160

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

RED3 control unit part number 157 157 157

RED3 rack sensor specifications 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 10.6

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 177 176 178

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point C

Rack position 4.8+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 12 10 14

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position 11.7+-0. 1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Rack limit *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1(9.5)

Boost pressure kPa 6.7 6.7 6.7

Boost pressure mmHg 50 50 50

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R1+1

Boost pressure kPa 14.7 13.4 16

Boost pressure mmHg 110 100 120

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position 11.7+-0. 1

Boost pressure kPa 24 24 24

Boost pressure mmHg 180 180 180

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0.8 0.5 1.1

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0.8 0.5 1.1

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1000

Remarks
Measure the actual advance angle.

Timer adjustment_05

Pump speed r/min 1080

Advance angle deg. 4.5 4.2 4.8

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)Variable speed specification: idling adjustment (5)Fix the lever at the full-load position at delivery. (6)Rack limit using the stop lever: R1 (7)Damper spring setting (8)Main spring setting (9)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
RT=1 TH=2.5mm R1=11.7+-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=14deg+-5deg b=6deg+-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=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the pin at R = bb
----------
aa=11.7+-0.1mm bb=52mm
----------
a=(33.5deg)+-5deg b=(37.5deg)+-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:

Illustration 4 g01633558
(5) 326-7322 Bracket As (13) 250-3895 Spacer (14) 8T-4896 Hard Washer (15) 4L-6459 Bolt
Install the new 326-7322 Bracket As (5) by using four new 250-3895 Spacers (13), four new 4L-6459 Bolts (15), and four new 8T-4896 Hard Washers (14) in the same place where the muffler was previously installed. Refer to Illustration 4.
Illustration 5 g01633569
(4) 326-7321 Connector As (11) 249-3108 Isolation Mount (12) 7X-0618 Hard Washer (16) 8T-4244 Nut (17) 8T-7930 Bolt (19) 8T-4223 Hard Washer
Install the new 326-7321 Connector As (4) on bracket assembly (5) by using three new 249-3108 Isolation Mounts (11), three new 8T-7930 Bolts (17), six new 7X-0618 Hard Washers (12), three new 8T-4223 Hard Washers (19), and three new 8T-4244 Nuts (16). Refer to Illustration 5.
Illustration 6 g01633576
(2) 326-7333 Brace (7) 326-7334 Brace (11) 249-3108 Isolation Mount (12) 7X-0618 Hard Washer (16) 8T-4244 Nut (18) 8T-4176 Bolt (19) 8T-4223 Hard Washer
Install a new 326-7333 Brace (2) and a new 326-7334 Brace (7) to connector assembly (4) by using two new 249-3108 Isolation Mounts (11), two new 8T-4176 Bolts (18), four new 7X-0618 Hard Washers (12), two new 8T-4223 Hard Washers (19) and two new 8T-4244 Nuts (16). Refer to Illustration 6.
Illustration 7 g01633578
(1) 326-7315 Diesel Particulate Filter Gp
Install the new 326-7315 Diesel Particulate Filter Gp (1) onto connector assembly (4). The weight of the diesel particulate filter group is approximately 72.5 kg (160 lb). Refer to Illustration 7.
Illustration 8 g01633590
(9) 326-7320 Filter Clamp Assembly (16) 8T-4244 Nut (19) 8T-4223 Hard Washer (20) 8T-4910 Bolt
Install two new 326-7320 Filter Clamp As (9) by using eight new 8T-4223 Hard Washers (19), four new 8T-4910 Bolts (20) and four new 8T-4244 Nuts (16). Refer to Illustration 8.
Illustration 9 g01633633
(10) 195-3068 Ejector (22) 5P-0597 Hose Clamp (23) 273-3000 Hose (24) 233-7182 Tube
Install the new 195-3068 Ejector (10) to the diesel particulate filter. Refer to Illustration 9.
Install the new 273-3000 Hose (23), and the new 233-7182 Tube (24) to the ejector by using four new 5P-0597 Hose Clamps (22). Refer to Illustration 9.
Illustration 10 g01633714
(6) 326-7328 Tube As (8) 328-8875 Adaptor As (25) 141-1480 Clamp As (27) 202-1838 V-Band Clamp (28) 243-2973 Bellows
Install the new 326-7328 Tube As (6) to the inlet module tube of the diesel particulate filter by using a new 141-1480 Clamp As (25). Refer to Illustration 10.
Install the new 243-2973 Bellows (28) to tube assembly (6) by using a new 202-1838 V-Band