106871-5200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5200 1068715200

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Service parts 106871-5200 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5441

3. GOVERNOR 105487-6281

4. SUPPLY PUMP

105237-4180

5. AUTOM. ADVANCE MECHANIS 105681-1200

6. COUPLING PLATE 105662-1240

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5800

11. Nozzle and Holder 16600-97068

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-6810

15. NOZZLE SET

Include in #1:

106871-5200 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5200 1068715200

Zexel num

Bosch num

Firm num

Name

106871-5200

INJECTION-PUMP ASSEMBLY
14CD PE8P PE

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 9.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 115 114 116

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting (6)Variable speed specification: idling adjustment (7)Fix the lever at the full-load position at delivery. (8)Main spring setting
----------
RT=1 TH=1.7mm SXL=9.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
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
----------
a=23deg+-3deg b=33deg+-5deg

Stop lever angle

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

Installation Procedure
The installation procedure that follows is specific for the listed machine.Diesel Particulate Filter Installation
Illustration 6 g01782176
(2) 331-9206 Bracket As (15) 8T-4223 Hard Washer (16) 8F-6437 Washer (17) 8T-4139 Bolt (19) 6V-8149 Nut
Install the new 331-9206 Bracket As (2) on top of the hood using two new 6V-87149 Nuts (19), one new 8F-6437 Washer (16), three new 8T-4223 Hard Washers (16), and two new 8T-4139 Bolts (17). Refer to Illustration 6.
Illustration 7 g01782178
(3) 331-9212 Bracket (20) 8T-3597 Weld Nut
Connect 331-9212 Bracket (3) to the hood and to bracket assembly (2) using four new 8T-3597 Weld Nuts (20), three new washers (16), one new hard washer (15), and four new bolts (17). Refer to Illustration 7.
Illustration 8 g01782181
(6) 295-3044 Exhaust Support Gp (Lower half)
Install the lower halves of 295-3044 Exhaust Support Gp (6) on bracket assembly (2) using two new washers (16), two new hard washers (15), and four new bolts (17). Refer to Illustration 8.
Illustration 9 g01782193
(1) 331-8928 Diesel Particulate Filter Gp (6) 295-3044 Exhaust Support Gp (Upper half) (6a) Bolt (6b) Hard washer (6c) Weld nut
Place 331-8928 Diesel Particulate Filter Gp (1) onto the two lower halves of exhaust support group (6). The weight of the diesel particulate filter group is approximately 44 kg (97 lb). Refer to Illustration 9.
Install the two upper halves of exhaust support group (6) onto the lower halves of exhaust support group (6) using four hard washers (6b), four weld nuts (6c), and four bolts (6a). Refer to Illustration 9.
Illustration 10 g01782194
(a) Outlet module tube (11) 7S-8735 Clamp (13) 255-2899 Tail Pipe As (18) 8T-4186 Bolt (21) 8T-4133 Nut
Connect the new 255-2899 Tail Pipe As (13) to outlet module tube (a) of diesel particulate filter group (1) using one new 7S-8735 Clamp (11), one new 8T-4186 Bolt (18) and one new 8T-4133 Nut (21). Refer to Illustration 10.
Illustration 11 g01782200
(b) Inlet module tube (4) 331-9214 Filter Tube As (9) 8T-6765 Pipe Plug (8) 241-6170 Plug (12) 209-4589 Clamp
Connect the new 331-9214 Filter Tube As (4) to inlet module tube (b) of diesel particulate filter group using one new 209-4589 Clamp (12). Refer to Illustration 11.
Install the new 8T-6765 Pipe Plug (9) and 241-6170 Plug (8) onto the respective bosses provided on filter tube assembly (4). Refer to Illustration 11.
Illustration 12 g01782206
(7) 270-0112 Bellows
Connect the new 270-0112 Bellows (7) to filter tube assembly (4) using one clamp new (12). Refer to Illustration 12.
Illustration 13 g01782215
(5) 331-9213 Filter Tube
Connect the new 331-9213 Filter Tube (5) to bellows (7) using one new clamp (12). Refer to Illustration 13.
Illustration 14 g01782235
(10) 7E-3870 Muffler Clamp (14) 146-9734 Exhaust Elbow
Connect the new 146-9734 Exhaust Elbow (14) to filter tube (5) using a new 7E-3870 Muffler Clamp (10). Refer to