106971-0600 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069710600

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-0600 1069710600

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Service parts 106971-0600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5470

3. GOVERNOR 105407-3510

4. SUPPLY PUMP 105237-1830

5. AUTOM. ADVANCE MECHANIS 105636-5070

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-4760

11. Nozzle and Holder 1660097005

12. Open Pre:MPa(Kqf/cm2) 22.6(230)

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-3440

15. NOZZLE SET

Include in #1:

106971-0600 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-0600 1069710600

Zexel num

Bosch num

Firm num

Name

106971-0600

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

Pre-stroke mm 3 2.95 3.05

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 13.3

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 165 163 167

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.9

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 132.6 130.6 134.6

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.3+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 17.8 15.8 19.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 500+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 2.3 1.8 2.8

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 3.5 3.5 3.5

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)Set idle sub-spring
----------
K=10
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the pump speed at aa (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=27deg+-5deg b=4deg+-5deg c=32deg+-3deg d=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=26deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=A a2=E r1=750r/min r2=750r/min Q1=165+-2mm3/st Q2=180+-2mm3/st c1=+-4% c2=+-4% a3=18 a4=15 r3=900r/min r4=750r/min

Information:

2. Removing Accessories
(1) Removing Fan(a) Reduce the tension applied by the tension pulley by pushing the alternator toward the engine, then remove the water pump drive belt (1).(b) Remove the fan mounting bolts (2), then remove the fan (3).(c) Remove the water pump pulley (4), which was previously retained by the fan mounting bolts (2).(2) Removing Thermostat FittingRemove the water outlet fitting (1), then remove the thermostat (2), thermostat fitting (3), water joint (4), and temperature joint (5) in that sequence. (3) Removing Exhaust and Intake Manifolds(a) Remove the exhaust manifold mounting bolts, then remove the exhaust manifold (1) and the gasket (2).(b) Remove the intake manifold mounting bolts, then remove the intake manifold (3) and the gasket (4). When refitting the manifolds, fit each gasket with the side marked "MANIFOLD" facing the manifold. (4) Removing Water PumpRemove the water pump mounting bolts, then remove the water pump (1). (5) Removing Alternator(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loosen the alternator brace bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator. (6) Removing Starter(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the start wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3). (7) Removing Oil Filter(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1). (8) Removing Fuel Filter(a) Remove the fuel pipe (1) that leads from the fuel tank and the fuel pipe (2) that leads to the fuel pump.(b) Remove the fuel filter (3) from the engine. (9) Removing Fuel Pipes(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the joints and clips from the fuel hose (2), then disconnect the fuel hose from the injector holders.
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
1 Fuel hose2 Fuel pipe3 Tie rod cover4 Tie rod spring5 Tie rod6 Injection pump7 Adjustment shim8 Control rack pin(a) Remove the tie rod cover (3).
Removing tie rod cover(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing Oil PumpRemove the oil pump's four mounting bolts, then remove the oil pump (1). (12) Removing InjectorDisconnect the fuel injection pipe (1) and the fuel hose (2) before removing the injector (3). 3. Refitting Accessories
3.1 General PointsRefit accessories by following the removal procedures in reverse. After refitting accessories, perform the following operations:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the cooling