101606-6981 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066981


101606-6981 INJECTION-PUMP ASSEMBLY
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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:

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

Test data 101606-6981
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

Test data 101606-6981
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

Test data 101606-6981
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

Test data 101606-6981
(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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