103860-0151 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1038600151

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 103860-0151 1038600151

Service parts 103860-0151 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103086-9140

3. GOVERNOR 105445-0870

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105649-0050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4133

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 29.4(300)

13. NOZZLE-HOLDER 105041-7112

14. NOZZLE 105015-6640

15. NOZZLE SET

Include in #1:

103860-0151 as INJECTION-PUMP ASSEMBLY

108822-2370 as _

108822-2371

Cross reference number

ZEXEL 103860-0151 1038600151

Zexel num

Bosch num

Firm num

Name

103860-0151

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 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500

Overflow valve 131425-1920

Overflow valve opening pressure kPa 206 172 240

Overflow valve opening pressure kgf/cm2 2.1 1.75 2.45

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-5- 6-2-7-8

Pre-stroke mm 3.8 3.75 3.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-4 deg. 77 76.5 77.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-6 deg. 167 166.5 167.5

Difference between angles 5
Cyl.1-2 deg. 212 211.5 212.5

Difference between angles 6
Cal 1-7 deg. 269.5 269 270

Difference between angles 7
Cal 1-8 deg. 301.5 301 302

Injection quantity adjustment

Adjusting point A

Rack position 14.8

Pump speed r/min 1000 1000 1000

Each cylinder's injection qty mm3/st. 451 443.8 458.2

Basic *

Fixing the lever *

Boost pressure kPa 56 56

Boost pressure mmHg 420 420

Injection quantity adjustment_02

Adjusting point B

Rack position 7.9+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 54.5 49.5 59.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 14.5

Boost pressure kPa 29.3 26.6 32

Boost pressure mmHg 220 200 240

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 16.6

Boost pressure kPa 46.7 40 53.4

Boost pressure mmHg 350 300 400

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Boost compensator stroke (4)Rack difference between N = N1 and N = N2
----------
K=23 RAL=17.1+0.2mm N1=1000r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=(37deg)+-5deg b=(31deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = aa, speed = bb. (2)Clearance between stopper bolt and lever must be cc.
----------
aa=5mm bb=100r/min cc=2+1mm
----------
a=16deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of spline gear's aligning mark at No 1 cylinder's beginning of injection (key position) (3)B.T.D.C.: aa (4)-
----------
aa=36deg
----------
a=(130deg)

Have questions with 103860-0151?

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