106871-2870 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068712870

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-2870 1068712870

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Cross reference number

ZEXEL 106871-2870 1068712870

Zexel num

Bosch num

Firm num

Name

106871-2870
106871-2871

MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9T2 *

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 11.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 156 151 161

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-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(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 156 155 157

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 70 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position (9.2)

Boost pressure kPa 4 4 4

Boost pressure mmHg 30 30 30

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(11.4)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 2.5 2 3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Boost compensator cancel stroke: BSL (3)Boost compensator stroke
----------
DL=4.3-0.2mm BSL=2.6mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=14deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=31deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Stopper bolt setting (2)Rack position = aa (3)Rack position bb (4)Free (at shipping)
----------
aa=4-0.5mm bb=14.6mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)

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=5.6mm
----------

Timing setting

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

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

Information:

Introduction
Injector height setting is extremely important during the engine assembly process. The recommended intervals that are specified in the Operation and Maintenance Manual must be followed.Problem
An issue has been identified with the correct injector height settings. Check the injector height. Bottoming of the fuel injector rocker arm may be caused by the injector height being to high or low. Bottoming of the fuel injector can create a crack at the nose of the fuel injector rocker arm through the first and second threads of the adjusting screw hole. Once the crack has started it can result in the breaking of the fuel injector rocker arm at the nose. Breaking of the fuel injector rocker arm will result in an immediate poor engine performance.Solution
Performing the recommended inspection of the fuel injector rocker arm at the specified intervals in the operation and maintenance manual is important. Inspect the height