Rating:
Information injection-pump assembly
ZEXEL
106871-8091
1068718091
Cross reference number
ZEXEL
106871-8091
1068718091
Zexel num
Bosch num
Firm num
Name
106871-8091
INJECTION-PUMP ASSEMBLY
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
134424-0820
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
1-8-6-2-
7-5-4-3
Pre-stroke
mm
4.8
4.74
4.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
162
160
164
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
24
24
Boost pressure
mmHg
180
180
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
171.6
165.6
177.6
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
24
24
Boost pressure
mmHg
180
180
Injection quantity adjustment_03
Adjusting point
E
Rack position
7.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
127.5
125.5
129.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
F
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
121
121
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_05
Adjusting point
G
Rack position
4.5+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.8
5.8
11.8
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
H
Rack position
-
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
180
177
183
Fixing the lever
*
Boost pressure
kPa
24
24
Boost pressure
mmHg
180
180
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
7.5
Boost pressure
kPa
4
1.3
6.7
Boost pressure
mmHg
30
10
50
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
7.9
Boost pressure
kPa
10.7
10.7
10.7
Boost pressure
mmHg
80
80
80
Timer adjustment
Pump speed
r/min
(950)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
2
1.7
2.3
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)RACK LIMIT
(2)Set idle at delivery
(3)Damper spring setting: DL
----------
DL=2.9-0.2mm
----------
----------
DL=2.9-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=17deg+-5deg
----------
----------
a=17deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)At delivery
(3)Point G setting
----------
aa=46mm
----------
a=20deg+-5deg b=33deg+-3deg c=34deg+-5deg
----------
aa=46mm
----------
a=20deg+-5deg b=33deg+-3deg c=34deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=39deg+-5deg b=48.5deg+-5deg
----------
----------
a=39deg+-5deg b=48.5deg+-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 limit adjustment
(1)Mount the joint (B).
(2)Select the shim (D) so that the rack limit's rack position is obtained at that time.
(3)Install the rod (E) to the block (C).
The distance between the pump end face and the rod (E) at rack limit must be L.
2. Rack sensor adjustment (-0020)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set at speed N.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(6)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)
----------
L=38-0.2mm N=950r/min Ra=(8.6)mm
----------
----------
L=38-0.2mm N=950r/min Ra=(8.6)mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
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106871-8091
INJECTION-PUMP ASSEMBLY