101691-6150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016916150

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101691-6150 1016916150

Service parts 101691-6150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-9470

3. GOVERNOR 105402-2350

4. SUPPLY PUMP

105210-5250

5. AUTOM. ADVANCE MECHANIS 105676-0730

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4271

11. Nozzle and Holder ME080082

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

13. NOZZLE-HOLDER 105048-3131

14. NOZZLE

105017-0100

15. NOZZLE SET

Include in #1:

101691-6150 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-8160 as _

104745-8161

Cross reference number

ZEXEL 101691-6150 1016916150

Zexel num

Bosch num

Firm num

Name

101691-6150

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.5 3.45 3.55

Beginning of injection position
Drive 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 9.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 69.2 68.2 70.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.1+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 7.5 6.2 8.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 75

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1100.

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Torque spring does not operate. (3)RACK LIMIT (4)At shipping (5)Main spring setting (6)Set idle sub-spring
----------
K=12
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At shipping
----------

----------
a=(8deg)+-5deg b=(23deg)+-5deg c=(2deg)

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(130deg)