106691-0420 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066910420

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106691-0420 1066910420

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Service parts 106691-0420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-5980

3. GOVERNOR 105487-5040

4. SUPPLY PUMP 105217-1780

5. AUTOM. ADVANCE MECHANIS 105681-0820

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7170

11. Nozzle and Holder 16600-96574

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/19.6{200}

13. NOZZLE-HOLDER 105030-4210

14. NOZZLE 105015-8420

15. NOZZLE SET

Include in #1:

106691-0420 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106691-0420 1066910420

Zexel num

Bosch num

Firm num

Name

106691-0420

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

Rack position
Point A R=A

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 8.3

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 126.3 124.3 128.3

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_02

Adjusting point C

Rack position 5.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 850

Advance angle deg. 0.5

Load 3/4

Timer adjustment_02

Pump speed r/min 950

Load 4/4

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 5 4.5 5.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

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 the stop lever: R1 (5)Excess fuel setting for starting (6)Damper spring setting (7)Variable speed specification: idling adjustment (8)Main spring setting
----------
RT=1 TH=2.4mm R1=11.8+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Stopper bolt setting
----------
aa=290r/min
----------
a=3.5deg+-5deg b=13.5deg+-5deg

0000000901

F:Full load I:Idle (1)At threaded hole above R = aa (2)Stopper bolt setting
----------
aa=17mm
----------
a=15deg+-5deg b=29deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=11.8+0.2mm
----------
a=35deg+-5deg b=35deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At rack position = aa (4)-
----------
aa=R1(11.2)mm
----------
a=(30deg)

Information:

The 169-3374 Injector Sleeve Removal Group is used to remove the brass injector sleeves on 3176 and 3176B Engines, only. This tool group is used with the 9U-6860 Sleeve Replacement Group . The tool group eliminates the tapping and threading operation of the current 9U-6860 Sleeve Replacement Group . The benefits of this method of sleeve removal are easier sleeve removal and little debris that could enter the engine. This tool group uses a crimping die and captured stud similar to the current 3100 Sleeve Removal Tool. This tool group can be used with the cylinder head either on or off the engine.Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:USA: 1-800-542-8665, Option 1International: 1-309-578-7372Injector Sleeve Removal
Remove the rocker arms from the cylinder being repaired.
Remove the injector.
Illustration 4 g02888499
Put Sleeve Stud (3) into Injector Sleeve
Drop 142-8280 Sleeve Stud (3) into the injector sleeve and ensure that stud is resting at the bottom of the injector sleeve. The flat disc part of the sleeve stud should be below the top edge of the brass sleeve.
Illustration 5 g02888500
Insert Crimping Swage (9) Into Bore And Over Sleeve Stud (3)
Apply a light coating of grease to the inside cutting edge of crimping swage (9) and insert into the injector bore. Make sure that the tool is resting on the top edge of the brass sleeve by turning or "wiggling" slightly. It is possible for the tool to rest on the casting ledge (indicated by the arrow) in the cylinder head. The threads of sleeve stud (3) should go into the center hole of crimping swage (9), as shown in Figure 5.
Illustration 6 g02888508
Drive Crimping Swage (9) Down Into Injector Sleeve
Using a large hammer, strike the top of crimping swage (9) firmly and squarely. Drive down into the injector bore until the bottom slot is level with the top deck of the cylinder head, as shown in Figure 6.
Illustration 7 g02888509
Remove Driving Swage (9) With Crows Foot Pry Bar (12)
Remove the crimping swage from the injector bore. If the tool is stuck in the bore, use a crows foot pry bar (12) in the slot to work out the tool. Many times there will be a small amount of brass caught between crimping swage (9) and the injector bore causing the tool to stick. When the tool is removed, the top of the brass sleeve should be rolled over, trapping sleeve stud (3) inside the injector sleeve.Note: The sharp edge of crimping swage (9) must remain sharp and free of nicks or damage. This tool may be resharpened only on the inside cutting edge. Any sharpening procedure that reduces the OD of the cutting edge will result in poor tool performance and tool sticking.
Illustration 8 g02888517
Insert Sleeve Jaw (4)
Insert 151-4833 Sleeve Jaw (4) into the injector bore. The sharp edge of the sleeve jaw is designed to lock the rolled-over brass material between the sleeve stud and the sleeve jaw. The sleeve stud is then prevented from