106861-0702 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068610702

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106861-0702 1068610702

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Cross reference number

ZEXEL 106861-0702 1068610702

Zexel num

Bosch num

Firm num

Name

106861-0702

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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 11.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 109 108 110

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 112 108 116

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.7+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 18.6 16.6 20.6

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 750

Advance angle deg. 1

Timer adjustment_04

Pump speed r/min 1000

Advance angle deg. 1.9 1.4 2.4

Timer adjustment_05

Pump speed r/min 1250+-25

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using the stop lever: R1 (2)Damper spring setting: DL (3)Variable speed specification: idling adjustment (4)Main spring setting (5)Set idle sub-spring
----------
R1=11.5mm DL=5.4-0.2mm
----------

Speed control lever angle

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

----------
a=15deg+-5deg b=10deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=11.5mm bb=32mm
----------
a=29.5deg+-5deg b=4deg+-5deg

Information:

(1) Crossbar (from 8B7548 Puller).(2) Spacer plate.(3) S1589 Bolt with two 1S379 Washers.(4) 1D4595 Bolt.(5) 3H465 Plate.(6) 1P2403 Dial Indicator.(7) 1P2394 Adapter Plate.(8) 1P2402 Gauge Body.Make reference to Cylinder Liner Projection in Testing and Adjusting for the complete procedure.1. Install gasket and spacer plate (2) with bolts (3) and two 1S379 Washers. Tighten bolts (3) evenly in four steps: 1st step ... 14 N m (10 lb ft)2nd step ... 35 N m (25 lb ft)3rd step ... 70 N m (50 lb ft)4th step ... 95 N m (70 lb ft)2. Install tools as shown. Tighten bolts (4) evenly in four steps: 1st step ... 7 N m (5 lb ft)2nd step ... 20 N m (15 lb ft)3rd step ... 35 N m (25 lb ft)4th step ... 70 N m (50 lb ft)3. Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area. Cylinder liner projection measurements for any cylinder liner must be ... 0.033 to 0.175 mm (.0013 to .0069 in)Maximum permissible difference between all four measurements ... 0.05 mm (.002 in)Maximum permissible difference between average projection of any two cylinder liners next to each other ... 0.05 mm (.002 in)Maximum permissible difference between average projection of all cylinder liners under one cylinder head ... 0.08 mm (.003 in) If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No. FMO55228 for complete instructions on the use of 8S3140 Counterboring Tool Arrangement. 4. Minimum permissible depth to machine counterbore to adjust cylinder liner projection ... 0.76 mm (.030 in) Maximum permissible depth to machine counterbore to adjust cylinder liner projection ... 1.14 mm (.045 in) install a 0.76 mm (.030 in) shim plus any added shims necessary to get the correct cylinder liner projection. Be sure that the 0.76 mm (.030 in) shim is directly under the cylinder liner flange.