101606-6081 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066081


101606-6081 INJECTION-PUMP ASSEMBLY
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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:

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

Test data 101606-6081
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=D15
----------

Speed control lever angle

Test data 101606-6081
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

Test data 101606-6081
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

Test data 101606-6081
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

Test data 101606-6081
(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)




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