106691-0220 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066910220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106691-0220 1066910220

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Service parts 106691-0220 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-5770

3. GOVERNOR 105488-9391

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105691-0130

6. COUPLING PLATE 105662-0880

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5520

11. Nozzle and Holder 16600-96507

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

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5100

15. NOZZLE SET

Include in #1:

106691-0220 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106691-0220 1066910220

Zexel num

Bosch num

Firm num

Name

106691-0220

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 R1(11.9)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 171 169 173

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point B

Rack position R2(12.6)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 186 183 189

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_03

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.4 9.4 11.4

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 R3(9.7)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 110 107 113

Max. variation between cylinders % 0 -4 4

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 (9.7)

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 (12.8)

Boost pressure kPa 24 24 24

Boost pressure mmHg 180 180 180

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Rack limit using stop lever (3)Boost compensator stroke: BCL (4)Rack difference between N = N1 and N = N2
----------
DL=3.9-0.2mm BCL=3.1+-0.1mm N1=1000r/min N2=600r/min
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(5.5deg) t1=1.5--sec. t2=1.5--sec.
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N1=1250++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.5+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
----------

----------
a=23deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)At threaded hole above R = aa
----------
aa=17mm
----------
a=22deg+-5deg b=(40.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=(12.8)mm bb=1+0.5mm
----------
a=24deg+-5deg b=33.5deg+-5deg

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1=5+-0.02V V2f=0.15+-0.03V V2i=2.35-0.03V
----------

Timing setting

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

----------
a=(20deg)

Information:

Intake and exhaust valve stems are to be coated with 8T2998 Break-in Lubricant prior to installation in the cylinder head. For removing and installation of valve guides and valve seat inserts, use 1U6685 Tool Group.(1) Exhaust valve.(2) Intake valve.(3) 7C4273 Spring for intake valves. Free length ... 71.0 mm (2.80 in)Assembled length ... 65.86 mm (2.593 in)Load at assembled length ... 217 22 N (49 5 lb)Minimum operating length ... 50.7 mm (2.00 in)Load at minimum operating length ... 858 40 N (193 9 lb)(3) 6I2307 Spring for exhaust valves. Free length ... 81 mm (3.19 in)Assembled length ... 70.8 mm (2.787 in)Load at assembled length ... 612 31 N (138 7 lb)Minimum operating length ... 59.0 mm (2.32 in)Load at minimum operating length ... 1325 66 N (298 15 lb)(4) Height to top of valve guides ... 23.0 0.5 mm (.906 .020 in)(5) Diameter of valve stems (new) ... 8.000 0.008 mm (.3150 .0003 in) "Use again" minimum diameter of valve ... 7.965 mm (.3136 in)Bore in valve guides with guides installed in head ... 8.045 0.010 mm (.3167 .0004 in)"Use again" maximum bore in valve guides with guides installed in head ... 8.080 mm (.3181 in)(6) Diameter of valve head: Intake valve ... 47.00 0.13 mm (1.850 .005 in)Exhaust valve ... 40.00 0.13 mm (1.575 .005 in)(7) Angle of valve faces: Intake valve ... 29.75 .25 degreesExhaust valve ... 45 .25 degrees (8) Diameter of valve seat inserts: Intake valve ... 50.000 0.013 mm (1.9685 .0005 in)Exhaust valve ... 43.000 0.013 mm (1.6929 .0005 in)Bore in head for valve seat insert:Intake valve ... 49.931 0.013 mm (1.9658 .0005 in)Exhaust valve ... 42.931 0.013 mm (1.6902 .0005 in)Valve seat insert must be shrunk by reduced temperature before installing in head.(9) Angle of valve seat inserts: Intake valve ... 30.25 1 degreesExhaust valve ... 45.5 1 degrees(10) Depth of bore in head for valve seat insert ... 10.00 0.13 mm (.394 .005 in)(11) Outside diameter of the seating face of the valve seat insert: Intake valve ... 45.88 0.085 mm (1.806 .003 in)Exhaust valve ... 39.135 0.046 mm (1.541 .002 in)(12) "Use again" thickness of valve lip: Intake valve ... 1.80 mm (.071 in)Exhaust valve ... 1.50 mm (.059 in)(13) Distance from head of valve to the cylinder head face (valve closed): Exhaust valveMaximum permissible ... 2.22 mm (.087 in)Minimum permissible ... 1.51 mm (.059 in)Intake valveMaximum permissible ... 2.05 mm (.081 in)Minimum permissible ... 1.13 mm (.044 in)