101608-1471 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081471


101608-1471 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101608-1471 1016081471

Service parts 101608-1471 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8391
3. GOVERNOR 105932-2011
4. SUPPLY PUMP 105210-6020
5. AUTOM. ADVANCE MECHANIS 105643-1150
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-7522
11. Nozzle and Holder ME072745
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}
13. NOZZLE-HOLDER 105041-3031
14. NOZZLE
15. NOZZLE SET 105019-0690

Include in #1:

101608-1471 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101608-1471 1016081471


Zexel num
Bosch num
Firm num
Name
101608-1471 
 
   
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   105780-8260
Bosch type code   9 430 610 133
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   18
Opening pressure kgf/cm2   184
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   131424-8420
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   11.9
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   108.5 105.2 111.8
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   9.5+-0.5
Pump speed r/min   260 260 260
Each cylinder's injection qty mm3/st.   11.5 9.8 13.2
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.9)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   108.5 107.5 109.5
Basic   *
Fixing the lever   *
Boost pressure kPa   26.7 26.7
Boost pressure mmHg   200 200
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.7
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   108.5 104.5 112.5
Fixing the lever   *
Boost pressure kPa   26.7 26.7
Boost pressure mmHg   200 200
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2[R1-0. 2]
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   112 108 116
Fixing the lever   *
Boost pressure kPa   26.7 26.7
Boost pressure mmHg   200 200
Injection quantity adjustment_06
Adjusting point   E
Rack position   R1+0.55
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   110 106 114
Fixing the lever   *
Boost pressure kPa   26.7 26.7
Boost pressure mmHg   200 200
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R2-0.85
Boost pressure kPa   4 2.7 5.3
Boost pressure mmHg   30 20 40
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2[R1-0. 2]
Boost pressure kPa   13.3 13.3 13.3
Boost pressure mmHg   100 100 100
Timer adjustment
Pump speed r/min   1000--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   950
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   3.5 3 4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-1471
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=M18 BCL=0.85+-0.1mm
----------

Speed control lever angle

Test data 101608-1471
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=18.5deg+-5deg b=(42deg)+-3deg

Stop lever angle

Test data 101608-1471
N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed = cc and rack position = dd. (3)R = approximately ee (speed lever full, speed = ff) (4)Free (at delivery)
----------
aa=1400r/min bb=7-0.5mm cc=275r/min dd=(8.4)mm ee=(16)mm ff=0r/min
----------
a=39.5deg+-5deg b=(28deg) 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 LEVER

Test data 101608-1471
(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(42deg)+-3deg c=18.5deg+-5deg

Timing setting

Test data 101608-1471
(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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