106873-2661 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068732661

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-2661 1068732661

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Service parts 106873-2661 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5222

3. GOVERNOR 105489-3652

4. SUPPLY PUMP 105237-4230

5. AUTOM. ADVANCE MECHANIS 105681-1100

6. COUPLING PLATE 105663-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7411

11. Nozzle and Holder ME160666

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105030-4451

14. NOZZLE

105015-9400

15. NOZZLE SET

Include in #1:

106873-2661 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106873-2661 1068732661

Zexel num

Bosch num

Firm num

Name

106873-2661

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 10.1

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 146 141.6 150.4

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(10.1)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 146 145 147

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 161.5 157.5 165.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 175 155 195

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)When air cylinder is operating. (3)Excess fuel setting for starting: SXL (4)Damper spring setting
----------
SXL=11.3+-0.1mm
----------

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
----------
aa=1275r/min bb=330r/min
----------
a=19deg+-5deg b=(11deg)+-5deg

0000000901

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

----------
a=10deg+-5deg b=22.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the hole at R = aa (3)Rack position bb (4)Stopper bolt setting
----------
aa=36mm bb=3.7-0.5mm
----------
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
----------
N1=325r/min Ra=5.4+-0.1mm
----------

0000001601 GOVERNOR TORQUE CONTROL

Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=- N3=- N4=1100r/min RF=10.1mm Dr1=1mm Dr2=0+0.3mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(40deg)

Information:

Pre-Start Inspection And Procedures
1. Make a "walk-around" inspection of the engine and components for the oil, water or fuel leaks and general appearance. Correct minor adjustments before they develop into major repair jobs.2. Check the crankcase oil level. Maintain the oil level between the ADD and FULL marks on the dipstick. See OIL SPECIFICATIONS for type of oil to use. 3. Check oil level(s) on driven equipment.
Check the engine coolant level when the engine is cool. If the engine is warm, steam may spray outward under high pressure and cause personal injury.
4. Check the engine jacket coolant level. Slowly turn the pressure cap until the cap is removed. Maintain coolant level to the base of the fill pipe. 5. Check the fuel supply. Keep fuel tanks full, as partially filled tanks will collect moisture. See the FUEL SPECIFICATIONS for type of fuel.Keep The Fuel Supply Clean
6. Open the raw water valve on the engine jacket heat exchanger system (if so equipped). Prime the raw water pump if the raw water system has been drained.7. Reset shutoff devices. See the topic, ATTACHMENTS, Emergency Shutoff Devices and Alarms.
OIL PRESSURE RESET
OVERSPEED RESETIf the engine is equipped with an air safety shutoff control, and was tripped to the shutoff position, reset the latch to the run position.
AIR SHUTOFF RESET8. Open the fuel supply valve. If the engine has not run for some time it may be necessary to prime the system. See the topic, PRIMING THE FUEL SYSTEM.9. Disconnect any battery charger which is not protected against starting motor drain.10. Disengage the clutch, or open the circuit breaker on a generator set.