106691-0191 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066910191

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106691-0191 1066910191

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Service parts 106691-0191 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-5780

3. GOVERNOR 105487-1992

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105681-4051

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6170

11. Nozzle and Holder 16600-96511

12. Open Pre:MPa(Kqf/cm2) 22.6{230}

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5800

15. NOZZLE SET

Include in #1:

106691-0191 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106691-0191 1066910191

Zexel num

Bosch num

Firm num

Name

106691-0191

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 3.65 3.6 3.7

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 11.1

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 162 160 164

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 10.8+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 162.2 159.2 165.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_03

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 13.2 12.2 14.2

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position R1(9.5)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 112 109 115

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point F

Rack position R1+0.5++

Pump speed r/min 40 40 40

Average injection quantity mm3/st. 110 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R1(9.5)

Boost pressure kPa 6.7 4 6.7

Boost pressure mmHg 50 30 50

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 11.7

Boost pressure kPa 24

Boost pressure mmHg 180

Timer adjustment

Pump speed r/min 200+100

Advance angle deg. 1.6 1.1 2.1

Remarks
Start

Timer adjustment_02

Pump speed r/min 500-150

Advance angle deg. 0 0 0

Timer adjustment_03

Pump speed r/min 910+80

Advance angle deg. 0 0 0

Timer adjustment_04

Pump speed r/min (1050)

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Damper spring setting: DL (4)Boost compensator stroke: BCL (5)Rack limit using the stop lever: R1 (6)Variable speed specification. (7)Main spring setting (8)Set idle sub-spring
----------
RT=1 TH=2.2mm DL=5-0.2mm BCL=(2.2)mm R1=11.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=26deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=20.5deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb. (2)Rack position = cc
----------
aa=1+0.5mm bb=0r/min cc=11.7mm
----------
a=28deg+-5deg b=30deg+-3deg

Timing setting

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

----------
a=(30deg)

Information:

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap on the radiator is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Drain the coolant from the cooling system into a suitable container for disposal.2. Remove the top radiator hose. 3. Remove four bolts (1) and the washers. Remove regulator housing (2) and the water temperature regulator as a unit. 4. Remove regulator housing gasket (4) from the regulator housing. Remove water temperature regulator (3).5. Remove the lip-type seal from the regulator housing. The following steps are for the installation of the water temperature regulator.6. Install the lip-type seal in the regulator housing with tool (A). Install the lip facing in toward the inside of the housing and until it makes contact with the counterbore in the housing. Lubricate the lip seal with glycerin.7. Install water temperature regulator (3) in the regulator housing.8. Put gasket (4) and regulator housing (2) in position, and install the four washers and bolts (1) that hold it.9. Connect the top radiator hose to the regulator housing.10. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.