106661-2110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066612110


106661-2110 INJECTION-PUMP ASSEMBLY
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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

Test data 106661-2110
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

Test data 106661-2110
(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.
----------
L=1-0.2mm N2=800r/min C2=(8.8deg) t1=2.5--sec. t2=2.5--sec.
----------
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

Test data 106661-2110
F:Full speed
----------

----------
a=14.5deg+-5deg

0000000901

Test data 106661-2110
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=28deg+-5deg b=29.5deg+-3deg

Stop lever angle

Test data 106661-2110
S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at shipping)
----------
aa=3.8-0.5mm
----------
a=38deg+-5deg b=37.5deg+7deg-5deg

0000001501 RACK SENSOR

Test data 106661-2110
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.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

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
----------
N1=325r/min Ra=5.7+-0.1mm
----------

0000001701 LEVER

Test data 106661-2110
(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

Test data 106661-2110
(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=9deg
----------
a=(7deg)




Have questions with 106661-2110?





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