101603-9930 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039930

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-9930 1016039930

Service parts 101603-9930 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6060

3. GOVERNOR 105492-7140

4. SUPPLY PUMP 105220-5190

5. AUTOM. ADVANCE MECHANIS 105643-0800

6. COUPLING PLATE 105661-0350

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5450

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3522

14. NOZZLE 105015-7110

15. NOZZLE SET

Include in #1:

101603-9930 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5931 as _

Cross reference number

ZEXEL 101603-9930 1016039930

Zexel num

Bosch num

Firm num

Name

101603-9930
101603-9931

INJECTION-PUMP ASSEMBLY
6110T * 14BF PE6AD PE

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 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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.2 4.15 4.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12.6

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 100.7 98.7 102.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_02

Adjusting point B

Rack position 12.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 93.4 87.4 99.4

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_03

Adjusting point C

Rack position 10.9

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 11.8 10.3 13.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 50

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position 12.5

Boost pressure kPa 3.3 3.3 6

Boost pressure mmHg 25 25 45

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position (13.6)

Boost pressure kPa 12 12 12

Boost pressure mmHg 90 90 90

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Damper spring setting
----------
RT=1 TH=2.1mm
----------

Speed control lever angle

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

----------
a=16deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=5.5deg+-5deg b=19.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

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