106971-0750 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069710750

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-0750 1069710750

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Service parts 106971-0750 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5470

3. GOVERNOR 105407-4200

4. SUPPLY PUMP 105237-1830

5. AUTOM. ADVANCE MECHANIS 105636-5140

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4590

11. Nozzle and Holder 1660097013

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-4180

15. NOZZLE SET

Include in #1:

106971-0750 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-0750 1069710750

Zexel num

Bosch num

Firm num

Name

106971-0750

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 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 13.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 177.2 175.2 179.2

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 12.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 153.6 151.6 155.6

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 6.8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 18.4 16.4 20.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min (550)

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 0.8 0.3 1.3

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)Rack difference between N = N1 and N = N2 (4)Idle sub spring setting: L1.
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K=11 N1=750r/min N2=500r/min L1=7.3+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
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aa=905r/min bb=750r/min
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a=4deg+-5deg b=33deg+-5deg c=8deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
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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)-
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a1=E a2=A r1=750r/min r2=750r/min Q1=177.2+-2mm3/st Q2=157.4+-2mm3/st c1=+-4% c2=+-4% a3=18 a4=15 r3=950r/min r4=750r/min

Timing setting

(1)Pump vertical direction (2)Position of the gear's standard threaded installation hole at the start of injection for the No. 10 cylinder. (3)- (4)-
----------

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a=(50deg)

Information:

Setting rack(4) Setting governor (setting maximum speed )(a) While applying the full load to the engine, hold the speed control lever in the specified maximum speed position.(b) Adjust the governor setting bolt (maximum speed setting bolt) to the specified speed position, and set it there.
Setting governor(5) Setting torque spring (optional specification)Set the speed control lever at the maximum speed, and apply the load to the engine. Turn the torque spring adjusting screw until the engine delivers the specified output at the specified speed. Fix the screw with the locknut, and install a cap to the lock nut.
Setting torque spring(6) Measuring speed variationMeasurement of speed variation at removal of load.(a) Operate the speed control to set the engine at the rated output and speed.(b) From this condition, instantaneously remove the load to put the engine into the no-load condition. Operate the engine with the speed control lever fixed.(c) The engine speed temporarily jumps up then lowers and stabilizes. Record the momentary maximum speed, stabilized speed, and time from the removal of the load to the stabilization of the speed.Measurement of speed variation at application of load.From the no-load condition, instantaneously apply the specified load to the engine. Record the momentary maximum speed, stabilized speed, and time from the application of the load to the stabilization of the speed.Calculation of speed variationCalculate the speed variation from the measured results. When the speed variation falls outside specified limits, adjust the governor notches.
Measuring speed variation(7) Adjusting speed variation (adjusting governor notches)(a) Adjust the speed variation by turning the adjusting screw of the swivel lever.(b) Remove the plug at the top of the governor, and set the speed control lever to the low idle speed position. The swivel lever turns up to reveal the head of the adjusting screw. Turn the adjusting screw with a flat-head screwdriver.(c) The speed variation decreases as the adjusting screw is tightened and increases as the adjusting screw is loosened. One notch equals a quarter turn of the adjusting screw and changes the engine speed by three to five revolutions.(d) Turning the adjusting screw changes the governor spring tension and hence the maximum speed. Readjust the governor setting bolt.(e) The maximum speed increases as the adjusting screw is tightened and decreases as the adjusting screw is loosened.
The adjusting screw can be loosened by 20 notches (or five turns) from the position where it is fully tightened. It is dangerous if the adjusting screw is loosened more.
Adjusting speed variation(8) SealingSeal each setting bolt.Break-in Operation
When the engine is overhauled, it should be mounted on a dynamometer and operated for break-in and inspection.Starting Up
(1) Before starting the engine, check the levels of coolant, engine oil and fuel, and bleed the fuel and cooling system.(2) With the fuel supply cut off, operate the starter and crank the engine for about 15 seconds to circulate engine oil.(3) Move the speed control lever slightly in the direction for increased fuel (do not move it to "full injection" position), and then turn the starter switch