101606-6081 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066081

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101606-6081 1016066081

Service parts 101606-6081 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9170

3. GOVERNOR 105931-5570

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0410

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7510

11. Nozzle and Holder ME076087

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4110

14. NOZZLE

105015-7440

15. NOZZLE SET

Include in #1:

101606-6081 as INJECTION-PUMP ASSEMBLY

Include in #2:

104742-1511 as _

Cross reference number

ZEXEL 101606-6081 1016066081

Zexel num

Bosch num

Firm num

Name

101606-6081

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 131424-5520

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 3.5 3.45 3.55

Beginning of injection position
Governor 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 -

Rack position 11.1

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 68 66 70

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

Each cylinder's injection qty mm3/st. 8.7 8.2 9.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 68 67 69

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 79.9 75.9 83.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position R1+0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 52.4 48.4 56.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 65 105

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 2.5 2 3

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=D15
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(46deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1400r/min bb=(6.5)mm cc=275r/min dd=(6.5)mm
----------
a=11.5deg+-5deg b=(27deg)+-5deg

0000001201

F:At operation, hold it in the full speed position. I:Idle (1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.) (2)Actual measurement
----------
aa=8mm bb=1490r/min
----------
a=15deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(1deg)