106691-0201 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066910201

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106691-0201 1066910201

Cross reference number

ZEXEL 106691-0201 1066910201

Zexel num

Bosch num

Firm num

Name

106691-0201

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 (drive side) 134424-1720

Overflow valve opening pressure (drive side) kPa 162 147 177

Overflow valve opening pressure (drive side) kgf/cm2 1.65 1.5 1.8

Overflow valve (governor side) 132424-0620

Overflow valve opening pressure (governor side) kPa 157 123 191

Overflow valve opening pressure (governor side) 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)Damper spring setting: DL (2)Boost compensator stroke (3)Rack limit using the stop lever: R1 (4)Variable speed specification. (5)Main spring setting (6)Set idle sub-spring
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DL=5-0.2mm R1=11.7+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=26deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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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
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aa=1+0.5mm bb=0r/min cc=11.7mm
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a=28deg+-5deg b=30deg+-3deg

0000001501 Q ADJUSTMENT PIPING

Tester fuel pipe A Fuel inlet B (C) Forked piping (D) Overflow valve Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
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