106871-7471 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068717471


106871-7471 INJECTION-PUMP ASSEMBLY
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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

Test data 106871-7471
N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
----------
SXL=10.8+-0.1mm DL=4.3-0.2mm
----------

Speed control lever angle

Test data 106871-7471
(1)Set the pump speed at aa (2)Set the pump speed at bb.
----------
aa=1150r/min bb=815r/min
----------
a=21deg+-5deg b=5deg+-5deg

0000000901

Test data 106871-7471
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=28deg+-3deg

Stop lever angle

Test data 106871-7471
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)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)

0000001501 RACK SENSOR

Test data 106871-7471
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.
----------
V1=5+-0.02V V2f=0.15+-0.03V V2i=2.35-0.03V
----------

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
----------
N1=325+-5r/min Ra=5.6mm
----------

0000001701 LEVER

Test data 106871-7471
(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.
----------
N1=815r/min N2=1150r/min
----------

Timing setting

Test data 106871-7471
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




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