106873-7880 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068737880

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-7880 1068737880

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Cross reference number

ZEXEL 106873-7880 1068737880

Zexel num

Bosch num

Firm num

Name

106873-7880

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 131424-4620

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 A

Rack position 10.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 151.8 148.8 154.8

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

Injection quantity adjustment_02

Adjusting point B

Rack position 5.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 15.5 12.9 18.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-0.7

Boost pressure kPa 34.7 33.4 36

Boost pressure mmHg 260 250 270

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(10.9)

Boost pressure kPa 48 41.3 54.7

Boost pressure mmHg 360 310 410

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 975

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Rack limit (operating at delivery) (4)Main spring setting (5)Set idle sub-spring (6)Boost compensator stroke: BCL
----------
K=10 BCL=0.7+-0.1mm
----------

Speed control lever angle

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

----------
a=22deg+-5deg b=4deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
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a=35deg+-5deg b=70deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=800r/min Ra=10.9mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(40deg)

Information:

2. Remove bolts (1) from the alternator bracket.3. Remove the bolts that hold plate (3), and remove the plate.4. Disconnect water line (2) from the air compressor. Turn the water line tee toward the lifting bracket in order to provide clearance to remove the head bolt. 5. Remove bolts (4) and (5) that hold the cylinder head assembly to the cylinder block.6. Fasten a hoist, and remove the cylinder head assembly. The weight is approximately 135 kg (300 lb.).
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
7. Remove the gasket, seals (6) and O-ring seal (7) from the spacer plate. The following steps are for installation of the cylinder head. Be sure a new gasket has been installed between the spacer plate and the cylinder block. See Remove And Install Spacer Plate.8. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (6) and two O-ring seals (7).9. Fasten a hoist, and put the cylinder head assembly in position on the cylinder block. 10. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown.a. Tighten bolts 1 through 20 in number sequence to a torque of 270 25 N m (200 18 lb.ft.). b. Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.d. Install the rocker shaft assemblies and push rods. See Install Rocker Shaft Assemblies And Push Rods.e. Tighten bolts 21 through 26 in number sequence to a torque of 270 25 N m (200 18 lb.ft.). f. Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.). g. Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.h. Tighten the 3/8" bolts (5) to a torque of 43 7 N m (32 5 lb.ft.). If the studs for the exhaust manifold were removed, install new studs, and tighten them to a torque of 25 4 N m (18 3 lb.ft.)11. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in.) for intake and 0.76 mm (.030 in.) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb.ft.).12. Install the valve cover bases and the inner fuel lines. see Install Rocker Shaft Assemblies And Push Rods.13. Install the valve covers. See Install Valve Covers.14. Install pate (3).15. Connect water line (2) to the air compressor.16. Install bolts (1) for the alternator bracket.17. Install the