Rating:
Information injection-pump assembly
ZEXEL
106651-2160
1066512160
Cross reference number
ZEXEL
106651-2160
1066512160
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
5.1
5.05
5.15
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
14
Pump speed
r/min
600
600
600
Each cylinder's injection qty
mm3/st.
167
162.8
171.2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
F
Rack position
5.7+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
167
166
168
Basic
*
Fixing the lever
*
Boost pressure
kPa
110.6
110.6
Boost pressure
mmHg
830
830
Injection quantity adjustment_04
Adjusting point
B
Rack position
12.4+-0.
5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
142
139
145
Fixing the lever
*
Boost pressure
kPa
110.6
110.6
Boost pressure
mmHg
830
830
Injection quantity adjustment_05
Adjusting point
G
Rack position
12.9+-0.
5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
151
147
155
Fixing the lever
*
Boost pressure
kPa
110.6
110.6
Boost pressure
mmHg
830
830
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2(10.6)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
100
97
103
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
100
80
120
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_08
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.6
15.9
21.3
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
(check)
(check)
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2(10.6)
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.4
Boost pressure
kPa
25.3
25.3
25.3
Boost pressure
mmHg
190
190
190
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
12.6
Boost pressure
kPa
61.3
60
62.6
Boost pressure
mmHg
460
450
470
Boost compensator adjustment_04
Pump speed
r/min
600
600
600
Rack position
R1(14)
Boost pressure
kPa
97.3
90.6
104
Boost pressure
mmHg
730
680
780
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Boost compensator cancel stroke: BSL
(3)Boost compensator stroke
(4)Rack difference between N = N1 and N = N2
----------
DL=5.6-0.2mm BSL=3.8mm N1=600r/min N2=1100r/min
----------
----------
DL=5.6-0.2mm BSL=3.8mm N1=600r/min N2=1100r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=4deg+-5deg
----------
----------
a=4deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=21deg+-5deg b=40deg+-3deg
----------
----------
a=21deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at delivery)
----------
aa=4.9-0.5mm bb=15.6mm
----------
a=30.5deg+-5deg b=(35.5deg) c=0deg+7deg-5deg
----------
aa=4.9-0.5mm bb=15.6mm
----------
a=30.5deg+-5deg b=(35.5deg) c=0deg+7deg-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325+-5r/min Ra=6mm
----------
----------
N1=325+-5r/min Ra=6mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(7deg)
----------
----------
a=(7deg)