106961-0111 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069610111

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106961-0111 1069610111

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Cross reference number

ZEXEL 106961-0111 1069610111

Zexel num

Bosch num

Firm num

Name

106961-0111

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle 105015-2780

Bosch type code DLLA166S374NP6

Nozzle holder 105031-4190

Opening pressure MPa 19.6

Opening pressure kgf/cm2 200

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-1050

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 10-9-4-3 -6-5-8-7 -2-1

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 10-9 deg. 45 44.5 45.5

Difference between angles 2
Cal 10-4 deg. 72 71.5 72.5

Difference between angles 3
Cal 10-3 deg. 117 116.5 117.5

Difference between angles 4
Cal 10-6 deg. 144 143.5 144.5

Difference between angles 5
Cal 10-5 deg. 189 188.5 189.5

Difference between angles 6
Cal 10-8 deg. 216 215.5 216.5

Difference between angles 7
Cal 10-7 deg. 261 260.5 261.5

Difference between angles 8
Cal 10-2 deg. 288 287.5 288.5

Difference between angles 9
Cal 10-1 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point A

Rack position 10.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 103 102 104

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.2

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 97 94 100

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 20 18 22

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 300+100

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 3 2.5 3.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 5.6 5.1 6.1

Timer adjustment_04

Pump speed r/min 1250+50

Advance angle deg. 8 7.5 8.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Beginning of damper spring operation: DL (4)Solenoid operation confirmation: Set the speed control lever in the full speed position. At pump speed N1 when the solenoid is operated, confirm that the idle rack position is R1 or less.
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K=10 RAL=10.9+-0.1mm DL=6-0.5mm N1=100r/min R1=1mm
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Speed control lever angle

F:Full speed I:Idle S:Stop
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----------
a=8deg+-5deg b=32deg+-3deg c=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=(29deg) b=(47deg)

Information:

Recommended Procedure With Chassis Dynamometer
Possible Causes/Corrections Minor Operating FaultsTo help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the "Primary Engine Checks" section. Fuel Ratio Control Out Of Adjustment Or DefectiveFollow the procedure in the Testing and Adjusting Section of this Service Manual. Check Engine PerformanceDo a Power Analysis Report (PAR), Level II, to check engine performance. Refer to LEBV2810 and SEHS7886 for the tooling and procedures to use. Be sure to make a record of the temperatures for inlet air, fuel (at filter base), lubricating oil and coolant. Make the necessary adjustments or repairs to the engine if needed.At this point, the governor fuel settings should be verified. See the Testing and Adjusting Section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see "Owner/Operator Input" section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.Recommended Procedure Without Chassis Dynamometer
Possible Causes/Corrections Minor Operating FaultsTo help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the "Primary Engine Checks" section. Fuel Ratio Control Out Of Adjustment Or DefectiveFollow the procedure in the Testing and Adjusting Section of this Service Manual. Fuel Injection Timing Not CorrectFollow the procedures in the Testing and Adjusting Section of this Service Manual. Check Engine PerformanceInstall the tooling and follow the procedure given in the Road Test section.At this point, the governor fuel settings should be verified. See the Testing and Adjusting Section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see "Owner/Operator Input" section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.