101607-6941 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076941


101607-6941 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101607-6941 1016076941

Service parts 101607-6941 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8770
3. GOVERNOR 105932-0730
4. SUPPLY PUMP 105210-4661
5. AUTOM. ADVANCE MECHANIS 105643-0520
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6780
11. Nozzle and Holder ME076787
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-3350
14. NOZZLE 105015-9300
15. NOZZLE SET

Include in #1:

101607-6941 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101607-6941 1016076941


Zexel num
Bosch num
Firm num
Name
101607-6941 
 
   
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   4.2 4.15 4.25
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   13
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   96.8 93.9 99.7
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.   10.2 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(13)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   96.8 95.8 97.8
Basic   *
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.35
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   100.3 96.3 104.3
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-0.6
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   66.9 62.9 70.9
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2(R1+0. 25)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   96.5 92.5 100.5
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 75 115
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   450 450 450
Rack position   R2-0.6
Boost pressure kPa   6 4.7 7.3
Boost pressure mmHg   45 35 55
Boost compensator adjustment_02
Pump speed r/min   450 450 450
Rack position   R2(R1+0. 25)
Boost pressure kPa   20 20 20
Boost pressure mmHg   150 150 150
Timer adjustment
Pump speed r/min   1200--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   2.5 2 3
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-6941
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=D24 BCL=0.6+-0.1mm
----------

Speed control lever angle

Test data 101607-6941
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(39deg)+-3deg

Stop lever angle

Test data 101607-6941
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. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee (non-injection rack position)
----------
aa=50mm bb=1400r/min cc=6.5-0.5mm dd=275r/min ee=(8.6)-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
----------

0000001601 TAMPER PROOF

Test data 101607-6941
1. Method for setting tamperproof proofing (1)Perform after governor adjustment (torque cam phase adjustment). (2)Increase the full rack position to aa using the load lever. (3)At N = N1, push in screw (A) until Ra. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is Rb. (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
aa=(0.4)mm N1=1400r/min Ra=(R1+0.1)+-0.1mm Rb=(R1+0.1)+-0.1mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

Timing setting

Test data 101607-6941
(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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