106661-2110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066612110

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106661-2110 1066612110

Service parts 106661-2110 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5600

3. GOVERNOR 105487-4890

4. SUPPLY PUMP 105207-1440

5. AUTOM. ADVANCE MECHANIS 105691-3370

6. COUPLING PLATE 105662-1100

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7730

11. Nozzle and Holder ME056804

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

13. NOZZLE-HOLDER 105031-4530

14. NOZZLE

105015-6150

15. NOZZLE SET

Include in #1:

106661-2110 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-2110 1066612110

Zexel num

Bosch num

Firm num

Name

106661-2110

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 131424-6920

Overflow valve opening pressure kPa 191 157 225

Overflow valve opening pressure kgf/cm2 1.95 1.6 2.3

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 1-5-3-6- 2-4

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 149 145.3 152.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 149 148 150

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 147.5 145.5 149.5

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_05

Adjusting point E

Rack position R1+1.25

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 174 170 178

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_06

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 131 91 171

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-1.7

Boost pressure kPa 6 6 6

Boost pressure mmHg 45 45 45

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1-0.8

Boost pressure kPa 10 8.7 11.3

Boost pressure mmHg 75 65 85

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position R1(10.6)

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator cancel stroke: BSL (3)Boost compensator stroke (4)Damper spring setting
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BSL=1.8mm
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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=(8.8deg) 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
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a=14.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=28deg+-5deg b=29.5deg+-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=3.8-0.5mm
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a=38deg+-5deg b=37.5deg+7deg-5deg

0000001501 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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0000001601 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=5.7+-0.1mm
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0000001701 LEVER

(A) Stopper bolt (B) Link (C) S/M lever (d) Nut (E) Ring (F) Nut (G) S/M lever pin (H) Stopper bolt (I) Torsion spring (J) Return spring (K) Accelerator lever (L) Output measurement circuit (M) Potentiometer terminal (N) Viewed from front. (P) Viewed from top. (1)Black (2)Blue-red (3)Blue-yellow Accelerator lever angle, potentiometer and stopper bolt adjustment 1. Accelerator lever angle adjustment (see Fig. 1) (1)Hold the load lever against the idle side stopper bolt and fix it in the idling position. (2)Screw in the accelerator lever stopper bolt (A) and back off the stopper bolt (A) from the position where the accelerator lever contacts the load lever and fix the nut. Tightening torque: 4.9~7 N.m (0.5~0.7 kgf.m) 2. Potentiometer adjustment (See fig 2 and fig 3) Apply DC5+-0.01V to between the potentiometer terminals (2) ~ (1) and measure the output voltage VF between (3) ~ (1). (1)Hold the load lever against the idle side stopper bolt and fix it in the idling position. (2)Adjust the S/M lever (C)'s lever angle using the link (B) so that X = 22.5+-3 deg , then fix nut (D). Tightening torque: 3.4~4.9 N.m (0.35~0.5 kgf.m) (3)Hold the load lever against the full side stopper bolt and fix it in the full position. (4)Adjust the potentiometer output voltage using the link (E) so that VF = 0.25+-0.1V, the temporarily fix nut (F). (5)Move the load lever several times between the idle side and the full side. Confirm that it moves smoothly and that output voltage VF = 0.05~0.5V. Then fix nut (F). Tightening torque: 3.4~4.9 N.m (0.35~0.5 kgf.m) 3. Step motor's idle side stopper bolt adjustment (See fig 3) (1)After completing accelerator lever angle and potentiometer adjustment, position the load lever against the idle stopper bolt and fix in the idling position. (2)Screw in stopper bolt (H) until the S/M lever pin (G) contacts the lever (C). (3)Return the stopper bolt (H) 10 deg+2 deg (approx. 5.7 turns) from the position in (2) above and fix using the nut. (Reference: lever angle Y = 39.5deg+2deg Tightening torque: 4.9~7 N.m (0.5~0.7 kgf.m) 4. Final confirmation Confirm that the load lever is returned to the idling position through the torsion spring (I) and one return spring (J). (Remove 1 return spring.)
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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)B.T.D.C.: aa (4)-
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aa=9deg
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a=(7deg)