106873-2530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068732530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-2530 1068732530

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Cross reference number

ZEXEL 106873-2530 1068732530

Zexel num

Bosch num

Firm num

Name

106873-2530

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 131424-7920

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 4.4 4.37 4.43

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25

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

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

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

Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 10.4

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 151.5 147 156

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.9+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 18 15.3 20.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.4)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 151.5 150.5 152.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 156 152 160

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 200 180 220

Fixing the lever *

Remarks
After startup boost setting

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting (4)When air cylinder is operating.
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SXL=11.2+-0.1mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
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N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Stopper bolt setting (4)Stopper bolt setting
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aa=1275r/min bb=870r/min
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a=18.5deg+-5deg b=(7.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=28deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at shipping)
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aa=3.7-0.5mm
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a=10.5deg+-5deg b=57deg+7deg-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
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N1=325r/min Ra=5.4+-0.1mm
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0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
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Timing setting

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

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a=(40deg)

Information:

Start By:a. remove valve covers 1. Remove bolts (1) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (2). 2. Use tool (A) to loosen fuel injection line (3) from fuel injection nozzle (4). 3. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (3). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 4. Remove bolts (5) that hold the rocker shaft assemblies to the cylinder head assembly.5. Remove rocker shaft assemblies (6). 6. Put identification marks on the push rods as to their location in the engine. Remove push rods (7). 7. Put identification marks on the bridges as to their location in the engine. Remove bridges (8) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies And Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (8) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb.) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 20 ° to 30 ° (1/3 to 1/2 of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position, and tighten the locknut to a torque of 30 4 N m (22 3 lb.ft.). Install original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (7). 4. Put rocker shaft assemblies (6) in position on the cylinder head assembly.5. Put clean engine oil on the threads of bolts (5) that hold the shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb.ft.). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb.ft.). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb.ft.).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (3). Tighten the fuel injection line adapter nuts (9) to a torque of 40 7 N m (30 5 lb.ft.) with tool (B).7. Tighten fuel injection line nut (10) to a torque of 40 7 N m (30 5 lb.ft.) with tool (A).8. Make adjustments to the valves until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.76 mm (.030 in.). See Valve Clearance Setting in Testing And Adjusting. Tighten the locknut to a torque of 30 4 N m (22 3