106871-5460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715460

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106871-5460 1068715460

Service parts 106871-5460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-7340

3. GOVERNOR 105489-5550

4. SUPPLY PUMP 105237-4710

5. AUTOM. ADVANCE MECHANIS 105683-0570

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4610

11. Nozzle and Holder 16600-97162

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

13. NOZZLE-HOLDER 105030-4571

14. NOZZLE 105025-1270

15. NOZZLE SET

Include in #1:

106871-5460 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5460 1068715460

Zexel num

Bosch num

Firm num

Name

106871-5460

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

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 10.7

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 126 125 127

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Solenoid boost comp. OFF *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.75

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 139 137 141

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Solenoid boost comp. OFF *

Injection quantity adjustment_03

Adjusting point D

Rack position 6+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 14 12 16

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Solenoid boost comp. OFF *

Injection quantity adjustment_04

Adjusting point E

Rack position R1(10.6)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 114.5 112.5 116.5

Fixing the lever *

Solenoid boost comp. ON *

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 900

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 4.75 4.45 5.05

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Rack limit using stop lever: RA (3)Damper spring setting (4)Rack difference between N = N1 and N = N2 (5)Variable speed specification: idling adjustment (6)Fix the lever at the full-load position at delivery. (7)Main spring setting
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RA=12.4+-0.1mm N1=1100r/min N2=600r/min
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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.)
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aa=290r/min
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a=15deg+-5deg b=6deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=64.3mm
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a=18.5deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the pin at R = bb
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aa=12.4+-0.1mm bb=52mm
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a=36deg+-5deg b=39deg+-5deg

0000001501 BCS

(A) Screw for precise adjustment (B) Pre-adjustment screw (C) Control rack, rack decrease direction (D) Rack limit 1. Solenoid boost compensator adjustment (1)Supply DC: V1 to the solenoid terminals and confirm solenoid operation. (2)With the solenoid ON, calculate L1 from the value of R1. [L1 = La + (10.5 - R1) +-0.2] (3)Adjust (B) to obtain L1. (4)Assemble the solenoid to the governor. (5)With the solenoid ON, readjust (B) so that R1 is within the allowance a. (6)With the solenoid OFF, perform all governor adjustments except rack limit adjustment. (7)Set the pump speed at N1 and turn the solenoid ON. (8)Adjust (A) so that R1 is within the allowance range a. (9)Set the pump speed at N1 and fix the load lever in the full position (10)Turn the solenoid switch ON and OFF several times and confirm that the difference in rack positions is within L2. (11)Set the rack limit. (12)Stamp the solenoid valve.
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V1=24V N1=400r/min N2=0r/min R1=10.6mm a=+-0.5mm La=31mm L1=(30.9)+-0.2mm L2=3.5~5mm
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Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
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a=(90deg)