106971-0802 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069710802

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-0802 1069710802

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Buy INJECTION-PUMP ASSEMBLY 106971-0802 zexel genuine, new aftermarket engine parts with delivery

Service parts 106971-0802 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5550

3. GOVERNOR 105487-5021

4. SUPPLY PUMP 105237-4190

5. AUTOM. ADVANCE MECHANIS 105681-0700

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7040

11. Nozzle and Holder 16600-97073

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

13. NOZZLE-HOLDER 105030-4190

14. NOZZLE

105015-8580

15. NOZZLE SET

Include in #1:

106971-0802 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-0802 1069710802

Zexel num

Bosch num

Firm num

Name

106971-0802

INJECTION-PUMP ASSEMBLY
14CE PE10P 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 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 3.65 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 9.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118.4 117.4 119.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.4+-0.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 118.1 116.1 120.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 6.7+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 10.4 8.4 12.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 155

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 875

Advance angle deg. 0.5

Load 3/4

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 1.1 0.6 1.6

Load 4/4

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Load 4/4

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 (6)Variable speed specification: idling adjustment (7)Fix the lever at the full-load position at delivery. (8)Main spring setting
----------
RT=1 TH=2.2mm SXL=10.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=(13deg)+-5deg b=6deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=23.5deg+-3deg

Stop lever angle

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

----------
a=12deg+-5deg b=64deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the start of injection for the No. 10 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

Removal of idler gearCamshaft End Play
Measure the camshaft end play, and, if the limit value is exceeded, replace the thrust plate.
Measurement of camshaft end playReversal of Crankcase
Gently lay the crankcase on its side, then turn the crankcase upside down.
Resting the crankcase with the oil pan on the bottom can cause the oil pan to crack.
Reversal of crankcaseRemoval of Oil Pan And Oil Pan Gasket
(1) Unscrew the oil pan mounting bolts, and detach the oil pan.(2) Remove the oil pan gasket.
Removal of oil pan and oil gasketRemoval of Oil Pump
Unscrew the oil pump set bolt, and pull out the oil pump.
Removal of oil pumpRemoval of Camshaft
Removal of camshaft(1) Position the camshaft gear so that the two lightening holes are on the top and bottom, then remove the thrust plate mounting bolts using the socket.(2) Pull out the camshaft from the crankcase.
Be careful not to damage the cams and bearing sections on the camshaft.
Removal of Front Plate
Removal of front plateUnscrew the front plate mounting bolts, and dismount the front plate (together with the injection pump) from the crankcase.Pistons, Connecting Rods, Crankshaft and Crankcase
When replacing the crankcase, remove all accessories (relief valve and others) carefully from the crankcase, and reinstall them on a new crankcase.Laying Crankcase on Its Side
Gently lay the crankcase on its side.
Laying crankcase on its sideMeasurement of Connecting Rod End Play
(1) Measure the clearance between the big-end of each connecting rod and the crankshaft (end play) with feeler gages. (2) If the measured clearance exceeds the limit value, replace the connecting rod.
Measurement of connecting rod End PlayRemoval of Connecting Rod Caps
(1) On each connecting rod and cap, put a mark indicating its cylinder No.(2) Remove the connecting rod caps.(3) For each removed connecting rod bearing (lower half), indicate the piston No. from which it was removed and the upper/lower identification. Be careful not to damage the bearings. Arrange the removed bearings in such a way that they can be reinstalled in their original positions during reassembly.
Removal of connecting rod capPreparation For Removal of Pistons
If carbon deposits are present at the upper sections of the cylinders, remove the carbon deposits with sandpaper and a cloth to facilitate piston removal.
Preparation for removal of pistonRemoval of Pistons
(1) Turn the crankshaft to bring the piston to be removed to the top dead center.(2) Using the wooden handle of a hammer, push the connecting rod on the cap contacting surface to remove the piston and connecting rod assembly from the top side of the cylinder.
Removal of pistonRemoval of Piston Ring
Using the piston ring pliers, remove the piston rings
Removal of piston ringRemoval of Piston Pins
Removal of piston pin(1) Using the snap ring pliers, remove the snap rings.(2) Pull out the piston pin, and separate the piston from the connecting rod.(3) If the piston pin cannot be remove easily, heat the piston with a piston heater or in hot water.Reversal of Crankcase
Gently stand the crankcase so that the oil pan mounting side faces up.
Reversal of crankcaseMeasurement of Crankshaft End Play
(1) With a dial gage positioned