106871-8350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068718350

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106871-8350 1068718350

Cross reference number

ZEXEL 106871-8350 1068718350

Zexel num

Bosch num

Firm num

Name

106871-8350

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
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 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_02

Adjusting point C

Rack position 8.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 175 169 181

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

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 25.3 25.3

Boost pressure mmHg 190 190

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 8.1

Boost pressure kPa 12 12 12

Boost pressure mmHg 90 90 90

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
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DL=2.9-0.2mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N3=800r/min C2=(7)deg t1=2--sec. t2=2--sec.
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N1=950+-50r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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a=17deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)At delivery (3)Point G setting
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aa=46mm
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a=20deg+-5deg b=36deg+-5deg c=37deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Free (at delivery) (4)Stopper bolt setting
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aa=11mm bb=2.5-0.5mm
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a=24deg+-5deg b=24deg+-5deg c=(40deg)

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)
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L=38-0.2mm N=950r/min Ra=(8.7)mm
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