101606-6771 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066771

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101606-6771 1016066771

Service parts 101606-6771 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9690

3. GOVERNOR 105931-5301

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0180

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder ME076000

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101606-6771 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-6143 as _

Cross reference number

ZEXEL 101606-6771 1016066771

Zexel num

Bosch num

Firm num

Name

101606-6771

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 3.3 3.25 3.35

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 10.9

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 51 49.5 52.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.7+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 10.2 8.7 11.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 51 50 52

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 77.2 73.2 81.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(10.9)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 46.3 42.3 50.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 14.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 63 83

Fixing the lever *

Rack limit *

Injection quantity adjustment_07

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 10 8.5 11.5

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2.7 2.2 3.2

Timer adjustment_04

Pump speed r/min 1500

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=B07
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb. Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1450r/min bb=6.3-0.5mm cc=275r/min dd=(8.3)mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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
----------

0000001601 TAMPER PROOF

1. Set the full load lever at N1 and Ra. 2. Set the full load position at Rb using the screw A. 3. Pressfit after applying glue to (B). 4. Then, readjust the full rack using the load lever. 5. Governing must begin at N2 when speed lever's full side set bolt is fully backed off.
----------
N1=700r/min N2=1650--r/min Ra=R1(10.9)+1mm Rb=R1(10.9)+0.6mm
----------

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=16deg
----------
a=(1deg)