101605-9180 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016059180

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101605-9180 1016059180

Service parts 101605-9180 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5170

3. GOVERNOR 105401-0540

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0510

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6970

11. Nozzle and Holder 16600-95011

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

13. NOZZLE-HOLDER 105031-4620

14. NOZZLE

105015-6600

15. NOZZLE SET

Include in #1:

101402-4330 as _

101605-9180 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101605-9180 1016059180

Zexel num

Bosch num

Firm num

Name

101605-9180

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 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 1-4-2-6- 3-5

Pre-stroke mm 2.75 2.7 2.8

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 10.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 97 95.5 98.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2

Pump speed r/min 1115 1115 1115

Average injection quantity mm3/st. 79.5 73.5 85.5

Fixing the rack *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

Injection quantity adjustment_03

Adjusting point C

Rack position R1(9.7)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 79 77 81

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position 6.4+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 9 12

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1(9.7)

Boost pressure kPa 20 17.3 22.7

Boost pressure mmHg 150 130 170

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 10.4

Boost pressure kPa 44 37.3 50.7

Boost pressure mmHg 330 280 380

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=10 L1=11.5+-0.2mm BCL=(0.7)+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=3deg+-5deg b=17deg+-5deg

Stop lever angle

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

----------
a=26.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0.
----------
aa=11.5+-0.2mm
----------
a=(15deg) b=(8deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(30deg)