106871-9051 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068719051

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-9051 1068719051

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Service parts 106871-9051 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5110

3. GOVERNOR 105487-5320

4. SUPPLY PUMP 105207-1460

5. AUTOM. ADVANCE MECHANIS 105636-2170

6. COUPLING PLATE 105663-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7431

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE

105015-7310

15. NOZZLE SET

Include in #1:

106871-9051 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-9051 1068719051

Zexel num

Bosch num

Firm num

Name

106871-9051
106871-9053

HYUNDAI

INJECTION-PUMP ASSEMBLY
8DC9 *

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 134424-1320

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 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 9.5

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 118 114.5 121.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point F

Rack position 5.8+-0.5

Pump speed r/min 450 450 450

Each cylinder's injection qty mm3/st. 17 15.3 18.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118 117 119

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 124 118.8 129.2

Difference in delivery mm3/st. 10.4 10.4 10.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Remarks
(check)

Injection quantity adjustment_06

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 135 175

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.8 1.1 2.5

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 3.5 3.5

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 6.5 6 7

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
----------
RT=1 TH=2.3mm SXL=(R1+0.2)+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=19deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=26deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at delivery) (5)R = cc
----------
aa=4-0.5mm bb=11.7mm cc=36mm
----------
a=45.5deg+7deg-5deg b=22deg+-5deg c=(10.5deg)

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=5.6+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

START BY:a. remove alternator and mounting groupb. remove water temperature regulator and manifold1. Drain the coolant from the engine. 2. Loosen the clamps on breather tube (1), and pull it back for clearance. 3. Remove bolt (2) from the cover on the side of the cylinder block. 4. Remove the three bolts that hold cover (3) to the water pump. Remove cover (3) from the water pump. 5. Remove the two bolts, and remove elbow (4) from bonnet (5). Remove the two bolts, and remove bonnet (5) from the water pump. It is not necessary to remove bolts (6). These bolts only hold the cover to the timing gear cover.6. Remove six long bolts (7) that hold the water pump to the timing gear cover. Remove water pump (8).Install Water Pump
1. Check the O-ring seals and gaskets, and make replacements if needed. 2. Make sure O-ring seal (1) is in position on the water pump. Put water pump (2) into position in the timing gear cover. Install the bolts that hold the water pump in place. 3. Make sure the gaskets are in place. Connect bonnet (3) to the water pump. Connect elbow (4) to the bonnet. 4. Make sure O-ring seal (5) is in position, and install cover (6) on the water pump. 5. Install bolt (7) on the cover on the side of the engine. 6. Put breather tube (8) in position, and install the clamps that hold it.7. Fill the cooling system to the correct level. See the Maintenance Guide.Disassemble Water Pump
START BY:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use tooling (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer and clean shaft