101696-9890 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016969890

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Information injection-pump assembly

ZEXEL 101696-9890 1016969890

Service parts 101696-9890 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-5070

3. GOVERNOR 105921-9600

4. SUPPLY PUMP

105220-7010

5. AUTOM. ADVANCE MECHANIS 105672-4040

6. COUPLING PLATE 105662-1620

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7690

11. Nozzle and Holder 16600-Z5672

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/19.6{200}

13. NOZZLE-HOLDER 105041-4200

14. NOZZLE

15. NOZZLE SET 105019-0960

Include in #1:

101696-9890 as INJECTION-PUMP ASSEMBLY

106671-7090 as _

Cross reference number

ZEXEL 101696-9890 1016969890

Zexel num

Bosch num

Firm num

Name

101696-9890

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 131425-0420

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.1 3.05 3.15

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 12.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 102 100.4 103.6

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 Z

Rack position 9.2+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 20 18.2 21.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 102 101 103

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+1.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 100 96 104

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. 15)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 114.5 110.5 118.5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_06

Adjusting point D

Rack position (R2-1.4)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 76.5 74.5 78.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 120 120 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position (R2-1.4)

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1+0. 15)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 4.5 4 5

Remarks
Measure the actual speed, stop

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)RACK LIMIT (4)Boost compensator stroke: BCL
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T1=M71 BCL=(1.4)mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=39mm
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a=20deg+-5deg b=40.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=25deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
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Ra=R1(12.9)mm N1=700r/min V1=3+-0.01V
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0000001601 LEVER

(a) Speed lever (B) Accelerator lever (C) Accelerator lever stopper bolt (D) Full speed side (E) idle side 1. Accelerator lever setting method With speed lever at idle position, from point S contact Back off the accelerator lever stopper bolt L and set. (Turn bolt L turns and set.)
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r=36mm L=1+0.5mm