101606-6981 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066981

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101606-6981 1016066981

Service parts 101606-6981 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8220

3. GOVERNOR 105931-6791

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-0660

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7130

11. Nozzle and Holder ME076614

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-4290

14. NOZZLE

105015-8470

15. NOZZLE SET

Include in #1:

101401-7223 as _

101401-7224

101606-6981 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101606-6981 1016066981

Zexel num

Bosch num

Firm num

Name

101606-6981

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 3.2 3.15 3.25

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 12.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 95.5 92.6 98.4

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. 10.1 8.6 11.6

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 95.5 94.5 96.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 101.5 97.5 105.5

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 99.7 95.7 103.7

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.6

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 102.5 98.5 106.5

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_07

Adjusting point I

Rack position 13.5+-0. 1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 65 105

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-1.3

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2-0.85

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position R2(R1+0. 6)

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1225

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 3 2.5 3.5

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: RAL (4)Boost compensator stroke: BCL
----------
T1=F06 RAL=13.5+-0.1mm BCL=1.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(40deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
----------
aa=50mm bb=1350r/min cc=6.5-0.5mm
----------
a=25deg+-5deg b=27deg+-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)