101691-9603 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919603

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101691-9603 1016919603

Service parts 101691-9603 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3391

3. GOVERNOR 105921-1293

4. SUPPLY PUMP 105220-5690

5. AUTOM. ADVANCE MECHANIS 105672-0041

6. COUPLING PLATE 105661-0541

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6970

11. Nozzle and Holder 16600-95011

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4620

14. NOZZLE

105015-6600

15. NOZZLE SET

Include in #1:

101691-9603 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-8720 as _

104745-8721

Cross reference number

ZEXEL 101691-9603 1016919603

Zexel num

Bosch num

Firm num

Name

101691-9603

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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-2-6- 3-5

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 13.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 106.4 104.8 108

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.9+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.6)

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 106.4 105.4 107.4

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 96.7 93.5 99.9

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_05

Adjusting point C

Rack position R2(12.7)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 62.9 61.9 63.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position 14.8+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 100

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2(12.7)

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R1-0.5

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position R1+0.1

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Timer adjustment

Pump speed r/min 920--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 870

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

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)RACK LIMIT
----------
T1=B36
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26.5deg+-5deg b=43deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

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