106871-5461 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068715461


106871-5461 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106871-5461 1068715461

Service parts 106871-5461 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106080-7340
3. GOVERNOR 105489-5551
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:

106871-5461 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-5461 1068715461


Zexel num
Bosch num
Firm num
Name
106871-5461 
 
   
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   11.65
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   138 136 140
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(10.4)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   109.5 107.5 111.5
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

Test data 106871-5461
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: DL (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
----------
RA=12.4+-0.1mm DL=5.5-0.2mm N1=1100r/min N2=600r/min
----------

Speed control lever angle

Test data 106871-5461
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=(15deg)+-5deg b=(5.5deg)+-5deg

0000000901

Test data 106871-5461
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=30.5deg+-3deg

Stop lever angle

Test data 106871-5461
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the pin at R = bb
----------
aa=12.4+-0.1mm bb=46mm
----------
a=36deg+-5deg b=38deg+-5deg

0000001501 BCS

Test data 106871-5461
(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.
----------
V1=24V N1=400r/min N2=0r/min R1=10.4mm a=+-0.5mm La=31mm L1=(30.9)+-0.2mm L2=3.5~5mm
----------

Timing setting

Test data 106871-5461
(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

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




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