106671-0980 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710980


106671-0980 INJECTION-PUMP ASSEMBLY
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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

Test data 106671-0980
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
----------
RT=1 TH=2.5mm
----------

Speed control lever angle

Test data 106671-0980
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 106671-0980
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=34.5deg+-3deg b=45deg+-5deg

Stop lever angle

Test data 106671-0980
N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=10.8mm
----------
a=32deg+-5deg b=32deg+-5deg

0000001501 RACK SENSOR

Test data 106671-0980
(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=10.8mm
----------

0000001601 BCS

Test data 106671-0980
(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+-0.5mm a=+-0.5mm L1=30.1+-0.2mm L2=3.5~5mm La=28mm
----------

Timing setting

Test data 106671-0980
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)




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