106861-2530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068612530


106861-2530 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106861-2530 1068612530

Cross reference number

ZEXEL 106861-2530 1068612530


Zexel num
Bosch num
Firm num
Name
106861-2530 
 
   
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   1-2-7-3- 4-5-6-8
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.   90 89.5 90.5
Difference between angles 3
Cal 1-3
deg.   135 134.5 135.5
Difference between angles 4
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 5
Cal 1-5
deg.   225 224.5 225.5
Difference between angles 6
Cal 1-6
deg.   270 269.5 270.5
Difference between angles 7
Cal 1-8
deg.   315 314.5 315.5
Injection quantity adjustment
Adjusting point   -
Rack position   12.1+-0. 5
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   152 147.6 156.4
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   18.5 16 21
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.   152 151 153
Basic   *
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(12.1)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   154 147.6 160.4
Difference in delivery mm3/st.   12.8 12.8 12.8
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
Injection quantity adjustment_05
Adjusting point   D
Rack position   R2(11.2)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   128 124.3 131.7
Fixing the lever   *
Boost pressure kPa   29.3 29.3
Boost pressure mmHg   220 220
Injection quantity adjustment_06
Adjusting point   E
Rack position   -
Pump speed r/min   200 200 200
Average injection quantity mm3/st.   140 120 160
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   9.9
Boost pressure kPa   2.7 2.7 2.7
Boost pressure mmHg   20 20 20
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R2(11.2)
Boost pressure kPa   29.3 28 30.6
Boost pressure mmHg   220 210 230
Boost compensator adjustment_03
Pump speed r/min   600 600 600
Rack position   R1(12.1)
Boost pressure kPa   53.3 46.6 60
Boost pressure mmHg   400 350 450
Timer adjustment
Pump speed r/min   930
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1100
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106861-2530
N:Pump speed R:Rack position (mm) (1)Rack limit using the stop lever: R1 (2)Boost compensator cancel stroke: BSL (3)Boost compensator stroke: BCL (4)Damper spring setting: DL
----------
R1=13+0.5mm BSL=2.6mm BCL=(2.2)+-0.1mm DL=5.8-0.2mm
----------

0000000901

Test data 106861-2530
F:Full load I:Idle
----------

----------
a=14deg+-5deg b=(22deg)+-3deg

Stop lever angle

Test data 106861-2530
N:Pump normal S:Stop the pump. (1)Using reverse lever (2)Rack position = aa, stopper bolt setting (3)Rack position bb
----------
aa=4.7-0.5mm bb=13+0.5mm
----------
a=3deg+-6deg b=37deg+-6deg

0000001501 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=6.7mm
----------

Timing setting

Test data 106861-2530
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




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