Rating:
Information injection-pump assembly
ZEXEL
106871-8610
1068718610
Cross reference number
ZEXEL
106871-8610
1068718610
Zexel num
Bosch num
Firm num
Name
106871-8610
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
134424-1020
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
4.5
4.44
4.5
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
-
Rack position
12.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
149.8
146.3
153.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
7+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12.1
9.1
15.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
149.8
147.8
151.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
148.7
142.7
154.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.15
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
150.2
144.2
156.2
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.15
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
142.3
136.3
148.3
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
185
185
205
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
660
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_03
Pump speed
r/min
880
Advance angle
deg.
1
0.7
1.3
Load
3/4
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
4.75
4.45
5.05
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=F15
----------
----------
T1=F15
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=35deg+-5deg b=(43deg)+-3deg
----------
aa=41mm
----------
a=35deg+-5deg b=(43deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper screw at speed lever full position, pump speed bb and rack position cc (non-injection rack position) . Then, confirm non-injection and measure the actual rack position at idle speed dd.
(3)After adjustment, apply red paint.
----------
aa=45mm bb=1150r/min cc=5-0.5mm dd=225r/min
----------
a=(40deg)+-5deg b=8deg+-5deg
----------
aa=45mm bb=1150r/min cc=5-0.5mm dd=225r/min
----------
a=(40deg)+-5deg b=8deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
Adjustment of the rack sensor (-2320)
1. Rack limit adjustment
(1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position.
(2)Install the rod (e) to the block (c).
(3)At the rack limit, set the distance between the pump end face and the rod (E) to L1.
2. Rack sensor
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at N1.
(3)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.)
(4)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V).
(5)Apply red paint to both the joint (b) and the nut (f) join, and the joint (b) and the pump join. Output voltage VR +-0.01(V), speed N1 r/min, rack position Ra mm
----------
L=43+-0.1mm N1=900r/min Ra=R1(12.1)+0.15mm
----------
----------
L=43+-0.1mm N1=900r/min Ra=R1(12.1)+0.15mm
----------
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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106871-8610
INJECTION-PUMP ASSEMBLY