101603-9790 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039790


101603-9790 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-9790 1016039790

Service parts 101603-9790 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5040
3. GOVERNOR 105921-5450
4. SUPPLY PUMP 105220-5800
5. AUTOM. ADVANCE MECHANIS 105672-0270
6. COUPLING PLATE 105661-0391
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6690
11. Nozzle and Holder 16600-Z5519
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105031-4650
14. NOZZLE 105015-6380
15. NOZZLE SET

Include in #1:

101603-9790 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-9790 1016039790


Zexel num
Bosch num
Firm num
Name
101603-9790 
 
   
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   134424-1520
Overflow valve opening pressure kPa   162 147 177
Overflow valve opening pressure kgf/cm2   1.65 1.5 1.8
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   3.4 3.35 3.45
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   12.3
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   79.3 77.7 80.9
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   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   10.4 8.6 12.2
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.3)
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   79.3 78.3 80.3
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.05
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   91 87 95
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 80 90
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1200--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   6.5 6.2 6.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-9790
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G08
----------

Speed control lever angle

Test data 101603-9790
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Bottom lever
----------
aa=39mm
----------
a=26.5deg+-5deg b=36deg+-3deg

Stop lever angle

Test data 101603-9790
N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

0000001501 LEVER

Test data 101603-9790
(a) Speed lever (B) Accelerator lever (C) Accelerator lever stopper bolt (D) Full speed side (E) idle side 1. Accelerator lever setting method With speed lever at idle position, from point S contact Back off the accelerator lever stopper bolt L and set. (Turn bolt L turns and set.)
----------

----------
r=36mm L=1+0.5mm

Timing setting

Test data 101603-9790
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




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