106871-2920 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068712920

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-2920 1068712920

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Service parts 106871-2920 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5820

3. GOVERNOR 105487-1590

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105681-0170

6. COUPLING PLATE 105663-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7150

11. Nozzle and Holder ME060110

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

13. NOZZLE-HOLDER 105031-4500

14. NOZZLE 105015-6580

15. NOZZLE SET

Include in #1:

106871-2920 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-2920 1068712920

Zexel num

Bosch num

Firm num

Name

106871-2920

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 1-2-7-3- 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 10

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 129 125.1 132.9

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(10)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 128 130

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 131.7 126.3 137.1

Difference in delivery mm3/st. 10.8 10.8 10.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 140 180

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 900

Advance angle deg. 1

Load 3/4

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Load 4/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Excess fuel setting for starting: SXL
----------
DL=4.3-0.2mm SXL=10.8+-0.1mm
----------

Speed control lever angle

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

----------
a=21deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=28deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at shipping)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-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:

Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The calibration of the crank terminate adjustment can increase the crank terminate speed or the calibration of the crank terminate adjustment can decrease the crank terminate speed. The crank terminate speed determines when the starting motor is disengaged. The starting motor is disengaged when the system voltage is cancelled by the crank termination speed. At the crank terminate speed, the engine must be able to run without the assistance of the starting motor.
Remove the lockwire and the seal from seal screw plug (5). Remove seal screw plug (5) from the access hole for the crank terminate adjusting screw.
Use a small screwdriver to lightly turn the crank terminate adjusting screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw twenty times. The crank terminate adjusting screw will vary the setting of a potentiometer that is inside of the ESS. The crank terminate adjusting screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Turn the crank terminate adjusting screw for twelve turns in the opposite direction of the "MAX" arrow or the counterclockwise direction. This will establish an approximate crank terminate setting.
Connect a voltmeter with the positive lead at terminal (ESS-12) and the negative lead at (ESS-5). Use a 6V-7070 Digital Multimeter or a voltmeter with the same accuracy. Start the engine. Record the engine rpm when the starting motor disengages. The starting motor disengages when the open circuit voltage is cancelled by the crank terminate setting. Refer to the Speed Specification Chart for the correct crank terminate setting.
If the setting in Step 4 is not correct, proceed with Steps 6, 7, and 8. If the setting is correct go to Step 8.
Stop the engine and turn the crank terminate adjusting screw for one full turn in the clockwise direction in order to increase the crank terminate speed. Turn the crank terminate adjusting screw for one full turn in the counterclockwise direction in order to decrease the crank terminate speed.
While the voltmeter is still connected, start the engine. Record the engine rpm when the starting motor disengages. The starting motor will disengage when the voltage is cancelled by the crank terminate speed. Repeat Steps 6 and 7 until the crank terminate speed is correct.
Install seal screw plug (5) in the access hole for the crank terminate adjusting screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the overspeed calibration and the oil step speed calibration are also complete.