101608-1521 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081521

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101608-1521 1016081521

Service parts 101608-1521 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8020

3. GOVERNOR 105932-2061

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105643-1170

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:

101606-0330 as _

101608-1521 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101608-1521 1016081521

Zexel num

Bosch num

Firm num

Name

101608-1521

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 12.2

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 110 106.7 113.3

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 280 280 280

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(12.2)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 110 109 111

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+0.6

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 111 107 115

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(R1-0. 55)

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 110 106 114

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-0.65

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 55)

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 1.5 2.5

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)Boost compensator stroke: BCL
----------
T1=M26 BCL=0.65+-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=40mm
----------
a=18.5deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1300r/min bb=7-0.5mm cc=275r/min dd=(8.6)mm
----------
a=11.5deg+-5deg b=28deg+-5deg

0000001501 LEVER

(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=39deg+-3deg c=18.5deg+-5deg

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=(2deg)