106871-3932 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068713932

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-3932 1068713932

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Cross reference number

ZEXEL 106871-3932 1068713932

Zexel num

Bosch num

Firm num

Name

106871-3932

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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 162 160 164

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 171.6 165.6 177.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_03

Adjusting point E

Rack position 7.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 127.5 125.5 129.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 121 121

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point G

Rack position 4.5+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.8 5.8 11.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 180 177 183

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 7.5

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 10 50

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 7.9

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min (950)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 2 1.7 2.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT (2)Set idle at delivery (3)Damper spring setting: DL
----------
DL=2.9-0.2mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)At delivery (3)Point G setting
----------
aa=46mm
----------
a=20deg+-5deg b=33deg+-3deg c=34deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Free (at delivery) (4)Stopper bolt setting
----------
aa=11mm bb=2.5-0.5mm
----------
a=24deg+-5deg b=24deg+-5deg c=(40deg)

Timing setting

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

----------
a=(80deg)

Information:

Parts Required For 4C-8180 Timing Tool Group
Refer to Chart A for item identification.Assemble and Set the 4C-8180 Timing Tool Group
1. Obtain a 108-2104 Plunger and Barrel Assembly. This part can be new or used. If the part is used, make sure it is in good working condition. The plunger should move freely in the barrel.
4C-8181 Timing Tool Assembly
(9) 8J-3819 Spring. (10) 1N-3257 Retainer Ring. (11) Plunger and barrel from 108-2104 Plunger and Barrel Assembly. (12) 4C-8178 Indicator Mount Bonnet. (14) 4C-8179 Bonnet Nut. (16) 2W-3429 Gear Segment (part of 108-2104). (17) 8N-0669 Bolt (part of 108-2104). (18) 4P-8704 Spring (part of 108-2104). (19) 9Y-2088 Washer.2. Make a 4C-8181 Timing Tool Assembly out of the 108-2104 Plunger and Barrel Assembly. The 4C-8181 Timing Tool Assembly is not a serviceable part. a. Remove and discard 8N-0669 Bolt (17), 2W-3429 Gear Segment (16), and 4P-8704 Spring (18) from the 108-2104 Plunger and Barrel Assembly.b. Assemble 8J-3819 Spring (9) and 9Y-2088 Washer (19) onto plunger. The 9Y-2088 Washer is part of the 108-2104 Plunger and Barrel Assembly.c. Install the 4C-8178 Indicator Mount Bonnet (12) onto the barrel using a 1N-3257 Retainer Ring (10).d. Slip 4C-8179 Bonnet Nut (14) over indicator mount bonnet (12).e. This tool is now a 4C-8181 Timing Tool Assembly (11).3. Assemble knurled gauge collar (3) onto gauge (5) by threading them together. Hand tighten the two parts. Make sure the gauging surfaces are clean and free of all debris, nicks, etc.4. Install 4C-8181 Timing Tool Assembly (11) into gauge collar (3).5. Thread bonnet nut (14) into gauge collar (3) and hand tighten with 9U-5120 Spanner Wrench (13). This will secure timing tool assembly (11) into gauge collar (3).6. Spring (9) on the timing tool assembly should make the end of the plunger extend approximately 30 mm (1.2 in) past the end of gauge (5).7. Push on the end of the plunger and make sure it travels freely (under spring force) in and out of the gauge block bore. If there is binding, disassemble and correct the problem.8. Install either a 5P-4814 Collet (6) or 4C-2982 Collet Assembly (7) into indicator mount bonnet (12).9. Install an indicator with a 5P-7262 Contact Point into collet (6 or 7). Use either a 6V-6106 Dial Indicator or an 8T-1002 Probe connected to an 8T-1001 Electronic Position Indicator.
Do not over tighten collet (6 or 7) holding the indicator. Over-tightening can result in damage to the indicator or the electronic position indicator probe.
10. Tighten collet (6 or 7) just enough to make sure the indicator or electronic position indicator probe will not move in collet.11. Zero the indicator by following this procedure. a. Place the 4C-8183 Gauge Plate (8) onto a flat surface.b. Carefully hold the entire 4C-8180 Timing Tool Group and place it on the gauge plate, with the end of the plunger contacting the plate.c. Push down on the entire assembly, compressing the spring, until the bottom of gauge (5) is in complete contact with gauge plate (8).
Zero The Timing Tool Assembly With