106661-2190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066612190


 

Information injection-pump assembly

ZEXEL 106661-2190 1066612190
106661-2190 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 106661-2190 1066612190


Zexel num
Bosch num
Firm num
Name
106661-2190 
 
   
INJECTION-PUMP ASSEMBLY
14CA PE6P,6PD PE

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   10.2
Pump speed r/min   650 650 650
Each cylinder's injection qty mm3/st.   138.5 135.1 141.9
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   6.5+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   17.5 14.9 20.1
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.2)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   138.5 137.5 139.5
Basic   *
Fixing the lever   *
Boost pressure kPa   27.3 27.3
Boost pressure mmHg   205 205
Injection quantity adjustment_04
Adjusting point   D
Rack position   R2(R1-1. 6)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   101.5 98.5 104.5
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_05
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   135 115 155
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R2(R1-1. 6)
Boost pressure kPa   5.3 5.3 5.3
Boost pressure mmHg   40 40 40
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R1(10.2)
Boost pressure kPa   14 14 14
Boost pressure mmHg   105 105 105
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1100
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106661-2190
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: BCL (4)Damper spring setting
----------
BSL=1.6mm BCL=1.6+-0.1mm
----------

Speed control lever angle

Test data 106661-2190
F:Full speed
----------

----------
a=15.5deg+-5deg

0000000901

Test data 106661-2190
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=31deg+-3deg

Stop lever angle

Test data 106661-2190
S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Free (at delivery)
----------
aa=3.4-0.5mm
----------
a=35.5+-5deg b=38.5deg+7deg-5deg

0000001501 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=6.2+-0.1mm
----------

Timing setting

Test data 106661-2190
(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=13deg
----------
a=(7deg)




Information:

Tachometer Error...To check, connect a tachometer of known accuracy to the engine. Run the engine and make a comparison of the readings of the vehicle and test tachometers. If vehicle tachometer is defective, make repairs as necessary or install a new tachometer.Engine Operated at High Altitude...Less oxygen at higher altitudes causes the engine horsepower to go down approximately three percent for each 1000 ft. above sea level. *Brakes Do Not Completely Release... Check the brakes by feeling all the brake drums. If the brakes do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck jacked up the wheels must rotate freely when turned by hand.Vehicle Operated in Too High a Gear... If the operator does not shift the truck correctly or operates the truck in a "lug" condition (using the truck in too high a gear for engine rpm to go up as accelerator pedal is pushed farther down, or using the truck in a gear where engine rpm goes down with accelerator pedal at maximum travel), poor vehicle performance is the result. For best engine performance do not lug the engine more than 600 rpm below its full load speed.Extra Engine Driven Equipment...Air compressors, hydraulic pumps, generators, and other engine driven equipment that has damage, or that was not installed correctly, or that is not in correct adjustment, can take more horsepower to drive than expected. If necessary, disconnect the equipment and test the engine.Speedometer Error...A damaged speedometer does not give the correct speed or the correct indication of fuel consumption. An indication of low speed can cause the operator to feel that he has a power problem.Speeds Too High...The need for more horsepower is easy to see as the speed of the vehicle is increased. This is especially true if the front of the vehicle has a large surface area. Your authorized dealer can give you the horsepower needs for a vehicle, and the horsepower necessary for different vehicle designs at different speeds.Overload on Vehicle *High Moving Resistance...Soft ground conditions cause a need for more horsepower. To see if the problem is the engine, test the vehicle on a surface known to be good, or test on a chassis dynamometer.High Wind Resistance...The horsepower needs for a truck can be divided into two parts. Part of the horsepower is used to move the vehicle and part is used to get through wind resistance. The horsepower necessary to get through the wind resistance will increase as the vehicle is used at higher speeds. Vehicles with a large front area have a higher wind resistance and take more horsepower than those with a small front area. Some types of trucks, for example those used for the transportation of automobiles and/or boats have high wind resistance even if the front area is small. Moving against the wind has the same effect on wind resistance as does higher vehicle speed.Power Loss in Drive Gears...It is possible for

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