106871-7471 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068717471

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106871-7471 1068717471

Cross reference number

ZEXEL 106871-7471 1068717471

Zexel num

Bosch num

Firm num

Name

106871-7471

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

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

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

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

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

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

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

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 10

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 129 125.1 132.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 128 130

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 131.7 126.3 137.1

Difference in delivery mm3/st. 10.8 10.8 10.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 140 180

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 900

Advance angle deg. 1

Load 3/4

Remarks
Q=121 (mm3/st) / N=700(r/min)

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Load 4/4

Remarks
Q=155 (mm3/st) / N=700 (r/min), end of advance

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
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SXL=10.8+-0.1mm DL=4.3-0.2mm
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Speed control lever angle

(1)Set the pump speed at aa (2)Set the pump speed at bb.
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aa=1150r/min bb=815r/min
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a=21deg+-5deg b=5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=28deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Stopper bolt setting (2)Rack position = aa (3)Rack position bb (4)Free (at shipping)
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aa=4-0.5mm bb=11.7mm
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a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1=5+-0.02V V2f=0.15+-0.03V V2i=2.35-0.03V
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0000001601 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
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N1=325+-5r/min Ra=5.6mm
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0000001701 LEVER

(A) Stopper (B) bolt Bolt c (D) Bolt (E) Lever Speed lever angle and speed lever setting procedure (1)Set the speed lever so that speed N = N1. (2)With the lever (E) contacting the stopper (A), fully tighten bolts (B) and (D). (3)Screw in bolt (C) and lock. (4)Set the speed lever at the full position so that N = N2.
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N1=815r/min N2=1150r/min
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