Rating:
Information injection-pump assembly
ZEXEL
106671-0610
1066710610
Cross reference number
ZEXEL
106671-0610
1066710610
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
1-4-2-6-
3-5
Pre-stroke
mm
3.65
3.6
3.7
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
13
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
183.9
181.9
185.9
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Injection quantity adjustment_02
Adjusting point
B
Rack position
12.3
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
169.8
166.8
172.8
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Injection quantity adjustment_03
Adjusting point
C
Rack position
12.8+-0.
5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
179.8
171.8
187.8
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Injection quantity adjustment_04
Adjusting point
D
Rack position
7.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12
11
13
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_05
Adjusting point
E
Rack position
R1(10.9)
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
123.4
121.4
125.4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R1(10.9)
Boost pressure
kPa
8.7
8
9.4
Boost pressure
mmHg
65
60
70
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R1(10.9)
+1.3
Boost pressure
kPa
28.7
28.7
28.7
Boost pressure
mmHg
215
215
215
Boost compensator adjustment_03
Pump speed
r/min
300
300
300
Rack position
13+0.2
Boost pressure
kPa
42.7
42.7
42.7
Boost pressure
mmHg
320
320
320
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
(2)Rack limit using stop lever
(3)Boost compensator stroke (at N = N1)
(4)Damper spring setting: DL
----------
N1=300r/min DL=6.8-0.2mm
----------
----------
N1=300r/min DL=6.8-0.2mm
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Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N4=800r/min C4=(7)deg t1=2--sec. t2=2--sec.
----------
N1=300r/min N2=900++r/min N3=1100r/min C1=7+-0.3deg C2=3++deg C3=4--deg P1=0kPa(0kgf/cm2) P2=196kPa(2kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
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L=1-0.2mm N4=800r/min C4=(7)deg t1=2--sec. t2=2--sec.
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N1=300r/min N2=900++r/min N3=1100r/min C1=7+-0.3deg C2=3++deg C3=4--deg P1=0kPa(0kgf/cm2) P2=196kPa(2kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=32deg+-5deg
----------
----------
a=32deg+-5deg
0000000901
F:Full load
I:Idle
(1)At threaded hole above R = aa
(2)Stopper bolt setting
----------
aa=17mm
----------
a=22deg+-5deg b=31.5deg+-3deg
----------
aa=17mm
----------
a=22deg+-5deg b=31.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
----------
aa=13+0.2mm
----------
a=14.5deg+-5deg b=39deg+-5deg
----------
aa=13+0.2mm
----------
a=14.5deg+-5deg b=39deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=600r/min Ra=13mm
----------
----------
N1=600r/min Ra=13mm
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Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
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a=(30deg)