101691-9611 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919611

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101691-9611 1016919611

Service parts 101691-9611 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-8040

3. GOVERNOR 105492-0210

4. SUPPLY PUMP 105220-5160

5. AUTOM. ADVANCE MECHANIS 105622-1450

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER

14. NOZZLE 105015-3390

15. NOZZLE SET

Include in #1:

101691-9611 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-8860 as _

104745-8861

Cross reference number

ZEXEL 101691-9611 1016919611

Zexel num

Bosch num

Firm num

Name

101691-9611

INJECTION-PUMP ASSEMBLY
6102Q *

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 1-5-3-6- 2-4

Pre-stroke mm 2.4 2.35 2.45

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 B

Rack position 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 50.5 49 52

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 10+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 9.4 8.1 10.7

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. 90 90

Fixing the lever *

Remarks
After startup boost setting

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. 4.5 4 5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 5.5 5.5 5.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL (5)Rack difference between N = N1 and N = N2
----------
RT=1 TH=1.8mm SXL=11.8+0.2mm DL=7.2-0.5mm N1=1400r/min N2=900r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=20deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=31deg+-3deg

Stop lever angle

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

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(90deg)