101608-1351 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081351

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101608-1351 1016081351

Service parts 101608-1351 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8760

3. GOVERNOR 105411-1731

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105672-9010

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4190

11. Nozzle and Holder ME078067

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3350

14. NOZZLE 105025-0370

15. NOZZLE SET

Include in #1:

101606-0130 as _

101608-1351 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101608-1351 1016081351

Zexel num

Bosch num

Firm num

Name

101608-1351

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 4.5 4.45 4.55

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 A

Rack position 10.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 106 105 107

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Injection quantity adjustment_02

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-0.9

Boost pressure kPa 20 17.3 22.7

Boost pressure mmHg 150 130 170

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(10.6)

Boost pressure kPa 30.7 24 37.4

Boost pressure mmHg 230 180 280

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_02

Pump speed r/min 450

Advance angle deg. 2 1.5 2.5

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min (550)

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 2.5 2 3

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Main spring setting (4)Set idle sub-spring (5)Boost compensator stroke: BCL
----------
K=13 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(30deg)+-5deg b=(20deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

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=10deg
----------
a=(1deg)