106961-0210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069610210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106961-0210 1069610210

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Cross reference number

ZEXEL 106961-0210 1069610210

Zexel num

Bosch num

Firm num

Name

106961-0210

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

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 10-9-4-3 -6-5-8-7 -2-1

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 10-9 deg. 45 44.5 45.5

Difference between angles 2
Cal 10-4 deg. 72 71.5 72.5

Difference between angles 3
Cal 10-3 deg. 117 116.5 117.5

Difference between angles 4
Cal 10-6 deg. 144 143.5 144.5

Difference between angles 5
Cal 10-5 deg. 189 188.5 189.5

Difference between angles 6
Cal 10-8 deg. 216 215.5 216.5

Difference between angles 7
Cal 10-7 deg. 261 260.5 261.5

Difference between angles 8
Cal 10-2 deg. 288 287.5 288.5

Difference between angles 9
Cal 10-1 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point A

Rack position 11.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 109 108 110

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 112 108 116

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.7

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 18.6 16.6 20.6

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.8

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1250+-25

Advance angle deg. 4 3.3 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Rack limit using the stop lever: R1 (4)Damper spring setting: DL (5)Main spring setting (6)Set idle sub-spring
----------
R1=11.5mm DL=5.4-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle
----------

----------
a=15deg+-5deg b=10deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=11.5mm bb=1+0.5mm
----------
a=5deg+-5deg b=34deg+-3deg

Information:

(1) Torque for bolt that holds the impeller ... 39 3 N m (28 2 lb ft)(2) Shaft diameter at carbon seal assembly seat area must be ... 19.10 0.05 mm (.752 .002 in) Use 4C9500 Quick Cure Primer to clean the water pump shaft and the ceramic ring seal counterbore in the pump housing.(3) Ring and water seal. Use a 125-9622 Seal Installation Tool and hand pressure to install the rubber seal and ceramic ring as a unit in the pump housing bore. Make sure the identification mark (holes or groove) on the ceramic ring face is installed inside the rubber seal.(4) Seal assembly. a. Remove the spring from the seal.b. Put clean water on the seal assembly as the only lubrication for assembly. Do not get any grease or oil on the seal faces.c. Do not stretch the rubber of the seal assembly at installation. If the seal is stretched, the service life is shortened.d. Use a 125-9622 Seal Installation Tool and hand pressure to install the seal assembly on the pump shaft until the carbon face makes light contact with the smooth face of the ceramic ring. The carbon seal assembly must rotate with the water pump shaft. Do not use any lubricant (except clean water) that will reduce the friction between the seal and the shaft.e. Install the carbon seal assembly spring.(5) Oil seal. Put a small amount of clean engine oil on the lip of the seal at assembly. Install it with the lip toward the bearings as shown.(6) Torque for bolt that holds the gear ... 215 40 N m (160 30 lb ft)Water Pump (135-4925 and 135-4926)
(1) With flat side towards housing install oil seal flush with housing using a suitable driver. DO NOT lubricate lip of seal.(2) Install Shaft. Shaft diameter at unitized seal assembly must be ... 19.10 .01 mm (.752 .0004 in). Using a 138-9299 Installation Tool over the shaft with the chamfer facing out, carefully insert the shaft into the oil seal. Position the shaft to center the oil seal lips on the shaft running surface. Then remove installation tool from shaft.(3) Install bearings. Slide the bearing assembly over the shaft and into the housing. Torque the bearing retainer plate bolts to ... 25 6 N m (19 4 lb ft)(4) Torque for gear retaining bolt ... 215 40 N m (158 30 lb ft)(5) Unitized seal. Using a 139-0088 Installation Tool and a suitable press to install the seal onto the pump shaft and into the housing bore, insure that the seal is fully seated in the housing bore. DO NOT use a hammer to install the seal as damage to ceramic sealing face will occur.(6) Bolt torque for the impeller retaining bolts is ... 39 3 N m (28 2 lb ft)