101603-9981 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039981

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-9981 1016039981

Service parts 101603-9981 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6100

3. GOVERNOR 105931-9860

4. SUPPLY PUMP 105210-5280

5. AUTOM. ADVANCE MECHANIS 105644-0520

6. COUPLING PLATE 105662-1490

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101472-0112 as _

101603-9981 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-9981 1016039981

Zexel num

Bosch num

Firm num

Name

101603-9981

DPICO

INJECTION-PUMP ASSEMBLY
D1146 * Q

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 131424-1520

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 6-2-4-1- 5-3

Pre-stroke mm 4.6 4.55 4.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 6-2 deg. 60 59.5 60.5

Difference between angles 2
Cal 6-4 deg. 120 119.5 120.5

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

Difference between angles 4
Cal 6-5 deg. 240 239.5 240.5

Difference between angles 5
Cal 6-3 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 74.8 73.2 76.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 10.2+-0. 5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 17 15.5 18.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 74.8 73.8 75.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 80.2 76.2 84.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 58.4 54.4 62.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 115 130

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Microswitch adjustment unnecessary. (4)RACK LIMIT
----------
T1=D58
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=65mm
----------
a=24deg+-5deg b=37deg+-3deg

Stop lever angle

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

----------
a=25deg+-5deg b=40deg+-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=(60deg)