101691-9923 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919923


 

Information injection-pump assembly

ZEXEL 101691-9923 1016919923
101691-9923 INJECTION-PUMP ASSEMBLY
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Service parts 101691-9923 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101069-3650
3. GOVERNOR 105921-2373
4. SUPPLY PUMP 105220-5690
5. AUTOM. ADVANCE MECHANIS 105614-3311
6. COUPLING PLATE 105661-0631
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5620
11. Nozzle and Holder 16600-95015
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105031-4620
14. NOZZLE 105015-7360
15. NOZZLE SET

Include in #1:

101691-9923 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101691-9923 1016919923


Zexel num
Bosch num
Firm num
Name
101691-9923 
 
   
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   6-2-600
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   3.7 3.65 3.75
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   -
Rack position   13.7
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   109 107.4 110.6
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.8+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9 7.2 10.8
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13.7)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   109 108 110
Basic   *
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   101.4 99.4 103.4
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(12.6)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   61.6 59.6 63.6
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   85 85 105
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R3(12)
Boost pressure kPa   4 2.7 5.3
Boost pressure mmHg   30 20 40
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R3+0.4
Boost pressure kPa   9.3 8 10.6
Boost pressure mmHg   70 60 80
Boost compensator adjustment_03
Pump speed r/min   600 600 600
Rack position   R1-0.6
Boost pressure kPa   17.3 17.3 17.3
Boost pressure mmHg   130 130 130
Timer adjustment
Pump speed r/min   920--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   870
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101691-9923
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B36 BCL=(1.1)+-0.1mm
----------

Speed control lever angle

Test data 101691-9923
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101691-9923
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

Test data 101691-9923
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




Information:

* When operating the vehicle downhill, do not coast or put the transmission in NEUTRAL.* Select the correct gear that does not allow the engine speed (rpm) to exceed the limits above and use the engine retarder and/or brakes to limit the speed of the truck.* A simple rule to follow is to select the same gear that would be required to go up the hill. However, DO NOT allow the engine to overspeed.For more information on economical operation of this engine, refer to form LEDT5092, Driving Techniques for Maximum Fuel Economy.Programmable Features
The 3176 has the programmable features of cruise control, PTO governing, vehicle speed limiting, high gears rpm limiting, low gears rpm limiting, TEL rpm limiting, idle shutdown timer and retarder coast/latch included in its functions.Cruise Control
Typical InstallationCruise control reduces driver fatigue and improves vehicle ride by eliminating throttle bounce. Cruise control can also reduce fuel consumption and driver to driver variations in a large fleet.* Vehicle speed MUST be ABOVE the low cruise control speed limit [typically 30 mph (48 km/h)].* Set the ON/OFF switch to the ON position.* Accelerate vehicle to desired speed.* Move the SET/RESUME switch momentarily into the SET position. The engine will maintain the speed that the truck is traveling when the SET switch is released. If the SET switch is held for more than one second, the truck speed will continue to increase until the SET switch is released. The cruise speed will then be set to the speed the truck is traveling when the SET switch is released.* Move the ON/OFF switch to the OFF position, or ...* Depress the clutch pedal, or ...* Depress the service brake pedal.* Return the ON/OFF switch to the ON position, and/or ...* Move the SET/RESUME switch momentarily into the RESUME position. The 3176 system remembers the last cruise control set speed as long as the engine is running.If the RESUME switch is held for more than one second, the 3176 will decrease the truck speed and a new set speed will be established when the RESUME switch is released.The throttle can be used to exceed the cruise control set speed, if the high cruise limit is lower than the vehicle speed limit. Releasing the throttle will return the truck to the previous cruise speed. The throttle override can be used to anticipate hills or for passing situations.To shift gears, the ON/OFF switch can be moved to the OFF position or disengage the clutch to deactivate the cruise control.After shifting gears, the cruise control can be reactivated by moving the ON/OFF switch to the ON position and/or momentarily setting the SET/RESUME switch in the RESUME position. The 3176 system may have a maximum cruise speed which has been specified by the owner of the truck. The cruise control will only function between the programmed Low Cruise Control Limit (LCC) and High Cruise Control Limit (HCC). The High Cruise Control set limit is also generally set at a lower mph (km/h) than the vehicle speed

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