106691-0220 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066910220

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106691-0220 1066910220

Service parts 106691-0220 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-5770

3. GOVERNOR 105488-9391

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105691-0130

6. COUPLING PLATE 105662-0880

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5520

11. Nozzle and Holder 16600-96507

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

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5100

15. NOZZLE SET

Include in #1:

106691-0220 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106691-0220 1066910220

Zexel num

Bosch num

Firm num

Name

106691-0220

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 3.65 3.6 3.7

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 R1(11.9)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 171 169 173

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point B

Rack position R2(12.6)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 186 183 189

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_03

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.4 9.4 11.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position R3(9.7)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 110 107 113

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position (9.7)

Boost pressure kPa 6.7 4 6.7

Boost pressure mmHg 50 30 50

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position (12.8)

Boost pressure kPa 24 24 24

Boost pressure mmHg 180 180 180

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Rack limit using stop lever (3)Boost compensator stroke: BCL (4)Rack difference between N = N1 and N = N2
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DL=3.9-0.2mm BCL=3.1+-0.1mm N1=1000r/min N2=600r/min
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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=(5.5deg) t1=1.5--sec. t2=1.5--sec.
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N1=1250++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.5+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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a=23deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At threaded hole above R = aa
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aa=17mm
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a=22deg+-5deg b=(40.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=(12.8)mm bb=1+0.5mm
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a=24deg+-5deg b=33.5deg+-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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