106873-3200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733200

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106873-3200 1068733200

Cross reference number

ZEXEL 106873-3200 1068733200

Zexel num

Bosch num

Firm num

Name

106873-3200

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 4.5 4.44 4.5

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 9.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 157.6 155.6 159.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 160.7 157.7 163.7

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.25+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 143.7 139.7 147.7

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 3.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point F

Rack position 9.85+-0. 1

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 178.5 174.5 182.5

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_06

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 188 188 208

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 700--

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 4.75 4.45 5.05

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting (6)Variable speed specification: idling adjustment (7)Main spring setting (8)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
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RT=0.8 TH=2.4mm SXL=9.85+-0.1mm N1=300r/min R1=3.9mm N2=1100r/min Q1=3mm3/st
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Stopper bolt setting
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a=15.5deg+-5deg b=19deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=42mm
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a=39deg+-5deg b=43.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (at delivery), set before governor adjustment (2)Set the stopper bolt (apply red paint). (3)Use the pin at R = bb (4)Lever free
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aa=12+-0.1mm bb=37mm
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a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg

0000001201

(1)Minimum - maximum speed specification (2)Variable speed specification (3)Actual measurement (4)Actual measurement
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0000001501 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt (G) Variable speed specifications (H) Minimum maximum speed specifications F:Full speed I:Idle 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
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L=1~2mm
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