106671-0980 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066710980


 

Information injection-pump assembly

ZEXEL 106671-0980 1066710980
106671-0980 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 106671-0980 zexel genuine, new aftermarket engine parts with delivery

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)




Information:

The problems in this chart are problems that do come about and are normally called "low power." These problems are not necessarily more common than engine problems, but they are possible problems which you need to read and check before an engine is disassembled.Read all of the items but make sure the first four are checked completely before making any engine test. Recommended Procedure1. 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 bad, make repairs as necessary or install a new tachometer.2. 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. See the RACK SETTING INFORMATION for the correct rack setting for the higher altitude operation.3. Brakes Do Not Completely Release Check the brakes by feeling all the brake drums. If the brakes of a wheel do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck lifted with a jack the wheels must have free rotation when turned by hand.4. 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.5. 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.6. Speedometer Error A bad 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.7. 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. Application personnel can give you the horsepower needs for a vehicle, and the horsepower necessary for different vehicle designs at different speeds.8. Overload on Vehicle See the 1100 SERIES APPLICATION SLIDE RULE (LEO-21446) for the correct load for the engine you have.9. 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.10. High Wind Resistance The horsepower needs for a

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