106873-2791 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068732791


106873-2791 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106873-2791 1068732791

Cross reference number

ZEXEL 106873-2791 1068732791


Zexel num
Bosch num
Firm num
Name
106873-2791 
 
   
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   131424-7920
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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   4.4 4.37 4.43
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   45 44.75 45.25
Difference between angles 2
Cal 1-7
deg.   90 89.75 90.25
Difference between angles 3
Cal 1-3
deg.   135 134.75 135.25
Difference between angles 4
Cal 1-4
deg.   180 179.75 180.25
Difference between angles 5
Cal 1-5
deg.   225 224.75 225.25
Difference between angles 6
Cal 1-6
deg.   270 269.75 270.25
Difference between angles 7
Cal 1-8
deg.   315 314.75 315.25
Injection quantity adjustment
Adjusting point   -
Rack position   10.2
Pump speed r/min   650 650 650
Each cylinder's injection qty mm3/st.   147.5 143.1 151.9
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   6.4+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   18 15.3 20.7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.2)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   147.5 146.5 148.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.9
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   164.5 160.5 168.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   180 160 200
Fixing the lever   *
Remarks
After startup boost setting
 

Test data Ex:

Governor adjustment

Test data 106873-2791
N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting (4)When air cylinder is operating.
----------
SXL=11.3+-0.1mm
----------

Timer adjustment

Test data 106873-2791
(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.
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 106873-2791
F:Full speed (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Stopper bolt setting (4)Stopper bolt setting
----------
aa=1275r/min bb=740r/min
----------
a=19.5deg+-5deg b=(8deg)+-5deg

0000000901

Test data 106873-2791
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=21deg+-3deg

Stop lever angle

Test data 106873-2791
N:Pump normal S:Stop the pump. (1)Drive side (2)Use the hole at R = aa (3)Rack position bb (4)Stopper bolt setting
----------
aa=36mm bb=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+7deg-5deg

0000001501 GOVERNOR TORQUE CONTROL

Test data 106873-2791
Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=(700)r/min N3=(940)r/min N4=1100r/min RF=R1(10.2)mm Dr1=0.9mm Dr2=0+0.3mm
----------

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=325r/min Ra=5.9+-0.1mm
----------

0000001701 RACK SENSOR

Test data 106873-2791
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
----------

0000001801 LEVER

Test data 106873-2791
(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=740r/min N2=1275r/min
----------

Timing setting

Test data 106873-2791
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(40deg)




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