106671-5010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715010


106671-5010 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106671-5010 1066715010

Service parts 106671-5010 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106061-5560
3. GOVERNOR 105487-4990
4. SUPPLY PUMP 105237-1900
5. AUTOM. ADVANCE MECHANIS 105691-3560
6. COUPLING PLATE 105663-0630
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7940
11. Nozzle and Holder 16600-96571
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}
13. NOZZLE-HOLDER 105030-4210
14. NOZZLE 105015-8410
15. NOZZLE SET

Include in #1:

106671-5010 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5010 1066715010


Zexel num
Bosch num
Firm num
Name
106671-5010 
 
   
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   132424-0620
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   11.7
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   188 186 190
Max. variation between cylinders %   0 -4 4
Basic   *
Fixing the lever   *
Solenoid boost comp. OFF   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Solenoid boost comp. OFF   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   9.35
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   123.4 121.4 125.4
Fixing the lever   *
Solenoid boost comp. ON   *

Test data Ex:

Governor adjustment

Test data 106671-5010
N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Rack limit using stop lever (3)Damper spring setting (4)Variable speed specification: idling adjustment (5)(Fix in the full position at delivery.) (6)Main spring setting
----------

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Timer adjustment

Test data 106671-5010
(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 N4=800r/min C4=(5.5deg) t1=2--sec. t2=2--sec.
----------
N1=300r/min N2=900++r/min N3=1100r/min C1=5.5+-0.3deg C2=3++deg C3=4--deg P1=0kPa(0kgf/cm2) P2=196kPa(2kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load

Speed control lever angle

Test data 106671-5010
F:Full speed I:Idle (1)(Pump speed = aa) (2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=(13deg)+-5deg b=5.5deg+-5deg

0000000901

Test data 106671-5010
F:Full load I:Idle (1)Stopper bolt setting (2)Accelerator lever angle after setting the accelerator lever stopper bolt
----------

----------
a=45deg+-5deg b=33.5deg+-3deg c=(2deg)

Stop lever angle

Test data 106671-5010
N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=11.7mm
----------
a=34.5deg+-5deg b=34.5deg+-5deg

0000001501 RACK SENSOR

Test data 106671-5010
(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)
----------
N1=600r/min Ra=11.7mm
----------

0000001601 BCS

Test data 106671-5010
(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.
----------
V1=24V N1=300r/min N2=0r/min R1=R2(9.35)mm a=+-0.5mm L1=26.85+-0.2mm L2=3.5~5mm La=28mm
----------

0000001701 LEVER

Test data 106671-5010
(A) Load lever (for cruise control) (B) idle stopper bolt (C) Accelerator lever stopper bolt For (D) Accelerator lever (E) Accelerator lever I:Idle Accelerator lever, stopper bolt setting procedure (1)Position the load lever (A; for autocruise) against the idle stopper bolt (B) and fix. (2)Screw in the accelerator lever stopper bolt (C). (3)Back off the stopper bolt (C) 1 turn from the position where the accelerator lever (D) contacts the load lever (A) and set.
----------

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Timing setting

Test data 106671-5010
(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=(30deg)




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