106671-0980 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710980

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106671-0980 1066710980

Service parts 106671-0980 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5580

3. GOVERNOR 105487-4960

4. SUPPLY PUMP 105217-1750

5. AUTOM. ADVANCE MECHANIS 105681-4180

6. COUPLING PLATE 105663-0640

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7030

11. Nozzle and Holder 16600-96573

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}

13. NOZZLE-HOLDER 105030-4210

14. NOZZLE 105015-8540

15. NOZZLE SET

Include in #1:

106671-0980 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-0980 1066710980

Zexel num

Bosch num

Firm num

Name

106671-0980

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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-2-6- 3-5

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

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

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

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

Injection quantity adjustment

Adjusting point A

Rack position 10.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 174.4 172.4 176.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Solenoid boost comp. OFF *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Solenoid boost comp. OFF *

Injection quantity adjustment_03

Adjusting point D

Rack position 8.4

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 107.4 105.4 109.4

Fixing the lever *

Solenoid boost comp. ON *

Timer adjustment

Pump speed r/min 300++

Advance angle deg. 1 0.5 1.5

Remarks
Start

Timer adjustment_02

Pump speed r/min 500-100

Advance angle deg. 0 0 0

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1050

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using stop lever (5)Damper spring setting (6)Variable speed specification: idling adjustment (7)Fix the lever at the full-load position at delivery. (8)Main spring setting
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RT=1 TH=2.5mm
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Speed control lever angle

F:Full speed I:Idle (1)(Pump speed = aa) (2)Set the stopper bolt (fixed at full-load position at delivery.)
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aa=290r/min
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a=(13deg)+-5deg b=5.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=34.5deg+-3deg b=45deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
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aa=10.8mm
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a=32deg+-5deg b=32deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=600r/min Ra=10.8mm
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0000001601 BCS

(A) Screw for precise adjustment (B) Pre-adjustment screw (C) Control rack, rack decrease direction (D) Rack limit 1. Solenoid boost compensator adjustment (1)Supply DC: V1 to the solenoid terminals and confirm solenoid operation. (2)With the solenoid ON, calculate L1 from the value of R1. [L1 = La - (10.5 - R1) +-0.2] (3)Adjust (B) to obtain L1. (4)Assemble the solenoid to the governor. (5)With the solenoid ON, readjust (B) so that R1 is within the allowance a. (6)With the solenoid OFF, perform all governor adjustments except rack limit adjustment. (7)Set the pump speed at N1 and turn the solenoid ON. (8)Adjust (A) so that R1 is within the allowance range a. (9)Set the pump speed at N1 and fix the load lever in the full position (10)Turn the solenoid switch ON and OFF several times and confirm that the difference in rack positions is within L2. (11)Set the rack limit. (12)Stamp the solenoid valve.
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V1=24V N1=300r/min N2=0r/min R1=R2+-0.5mm a=+-0.5mm L1=30.1+-0.2mm L2=3.5~5mm La=28mm
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