106971-2000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069712000

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106971-2000 1069712000

Service parts 106971-2000 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5360

3. GOVERNOR 105487-3730

4. SUPPLY PUMP 105237-1321

5. AUTOM. ADVANCE MECHANIS 105639-1160

6. COUPLING PLATE 105663-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5831

11. Nozzle and Holder ME066499

12. Open Pre:MPa(Kqf/cm2) 17.7(180)/21.6(220)

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE 105015-5440

15. NOZZLE SET

Include in #1:

106971-2000 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-2000 1069712000

Zexel num

Bosch num

Firm num

Name

106971-2000

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 131424-4620

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 1-2-7-8- 5-6-3-4- 9-10

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 72 71.5 72.5

Difference between angles 3
Cal 1-8 deg. 117 116.5 117.5

Difference between angles 4
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 5
Cal 1-6 deg. 189 188.5 189.5

Difference between angles 6
Cal 1-3 deg. 216 215.5 216.5

Difference between angles 7
Cal 1-4 deg. 261 260.5 261.5

Difference between angles 8
Cal 1-9 deg. 288 287.5 288.5

Difference between angles 9
Cal 1-10 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point -

Rack position 12.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 168 163 173

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.6+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 168 167 169

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R2(11.9)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 162 159 165

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 90 170

Fixing the lever *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-1.5

Boost pressure kPa 10 10 10

Boost pressure mmHg 75 75 75

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1-1

Boost pressure kPa 28 26.7 29.3

Boost pressure mmHg 210 200 220

Boost compensator adjustment_03

Pump speed r/min 650 650 650

Rack position R1(12.6)

Boost pressure kPa 64.7 64.7 64.7

Boost pressure mmHg 485 485 485

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Boost compensator cancel stroke: BSL (2)Damper spring setting: DL (3)Boost compensator stroke
----------
BSL=1.6mm DL=4.8-0.2mm
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Speed control lever angle

F:Full speed (1)Set the pump speed at aa (2)When pump speed set at bb
----------
aa=(1150)r/min bb=695+-5r/min
----------
a=(15deg)+-5deg b=(8deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

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a=10deg+-5deg b=(33deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Lever free (at delivery) (5)R = cc
----------
aa=4-0.5mm bb=14.6mm cc=36mm
----------
a=38.5deg+-5deg b=33deg+-5deg c=(22.5deg)

0000001501 RACK SENSOR

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
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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=325+-5r/min Ra=6.1mm
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0000001701 LEVER

(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.
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N1=695+-5r/min N2=(1150)r/min
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