106871-5210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-5210 1068715210

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Service parts 106871-5210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5431

3. GOVERNOR 105487-6450

4. SUPPLY PUMP 105237-6020

5. AUTOM. ADVANCE MECHANIS 105683-0190

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:

106871-5210 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5210 1068715210

Zexel num

Bosch num

Firm num

Name

106871-5210

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 10.6

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 139.5 138.5 140.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point D

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 *

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min (780)

Advance angle deg. 1 0.7 1.3

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 1100

Advance angle deg. 4.75 4.45 5.05

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=2.9mm SXL=11+-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=6.5deg+-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=28.5deg+-3deg

Stop lever angle

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

Illustration 4 g01784824
Right side view of machine (A) Hood and guard group (B) Lines group (Air) (C) Air cleaner
Illustration 5 g01784914
Front view of machineInstallation Procedure
The installation procedure that follows is specific for the listed machine.Diesel Particulate Filter Installation
Illustration 6 g01784177
(2) 331-8935 Bracket (12) 5P-8245 Hard Washer (13) 6V-8149 Nut (14) 8F-6437 Washer (15) 8T-4956 Bolt
Place two new 331-8935 Brackets (2) parallel to each other on top of the hood. Secure the brackets by using four new 8F-6437 Washers (14), four new 5P-8245 Hard Washers (12), four new 6V-8149 Nuts (13) and four new 8T-4956 Bolts (15). Refer to Illustration 6.
Illustration 7 g01784193
(5) 295-3044 Exhaust Support Gp (Lower half) (14) 8F-6437 Washer (15) 8T-4956 Bolt
Install the two lower halves of the new 295-3044 Exhaust Support Gp (5) onto two brackets (2) using four new 8F-6437 Washers (14) and four new 8T-4956 Bolts (15). Refer to Illustration 7.
Illustration 8 g01784213
(1) 331-8928 Diesel Particulate Filter Gp (5a) Clamp As (Upper half) (5b) Bolts (5c) Hard Washers (5d) Weld Nuts
Place 331-8928 Diesel Particulate Filter Gp (1) onto the two lower halves of exhaust support group (5). The weight of the diesel particulate filter group is approximately 43.6 kg (96.1 lb). Refer to Illustration 8.
Install the two upper clamp assemblies (5a) onto the two lower halves of exhaust support group (5) by using four hard washers (5c), four weld nuts (5d) and four bolts (5b). Refer to Illustration 8.
Illustration 9 g01784214
(9) 174-5414 Clamp (11) 255-2899 Tail Pipe As
Install the new 255-2899 Tail Pipe As (11) to the outlet module tube of the diesel particulate filter group. Refer to Illustration 9.
Secure tail pipe assembly (11) to the outlet module tube of diesel particulate filter group by using a new 174-5414 Clamp (9). Refer to Illustration 9.
Illustration 10 g01784215
(3) 331-9047 Filter Tube As (7) 241-6170 Plug (8) 8T-6765 Pipe Plug (10) 209-4589 Clamp
Install the new 331-9047 Filter Tube As (3) to the inlet module tube of the diesel particulate filter group. Refer to Illustration 10.
Secure filter tube assembly (3) to the inlet module tube of the diesel particulate filter group by using one new 209-4589 Clamp (10). Refer to Illustration 10.
Install the new 241-6170 Plug (7) and 8T-6765 Pipe Plug (8) onto the bosses that are provided on filter tube assembly (3). Refer to Illustration 10.
Illustration 11 g01784216
(6) 270-0112 Bellows (10) 209-4589 Clamp
Install the new 270-0112 Bellows (6) to filter tube assembly (3). Refer to Illustration 11.
Secure bellows (6) to filter tube assembly (3) by using one new 209-4589 Clamp (10). Refer to Illustration 11.
Illustration 12 g01784217
(4) 331-8934 Filter Tube (10) 209-4589 Clamp
Install the new 331-8934 Filter Tube (4) into bellows (6). Refer to Illustration 12.
Secure filter tube (4) to bellows (6) by using one new 209-4589 Clamp (10). Refer to Illustration 12.
Connect