101603-9100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039100

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9100 1016039100

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Service parts 101603-9100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9090

3. GOVERNOR 105410-9220

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0350

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101402-4222 as _

101603-9100 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-9100 1016039100

Zexel num

Bosch num

Firm num

Name

101603-9100

DPICO

INJECTION-PUMP ASSEMBLY
6D16 * Q

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor 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 10

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 58.8 57.8 59.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8.6 7.1 10.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 71 61 81

Fixing the lever *

Timer adjustment

Pump speed r/min 1000++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1000.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0.5 0.5 0.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Rack difference between N = N1 and N = N2
----------
K=8 N1=1000r/min N2=400r/min
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=27deg+-5deg

Stop lever angle

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

----------
a=2.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(2deg)

Information:

Illustration 4 g01456650
Position 253-7967 Bracket (6) behind the turbocharger in the location that is shown in Illustration 4.
Illustration 5 g01879437
(6) 253-7967 Bracket (15) 8T-4121 Hard Washer (17) 8T-4195 Bolt
Install bracket (6) by using four 8T-4195 Bolts (17) and four 8T-4121 Hard Washers (15). Refer to Illustration 5.
Illustration 6 g01879493
(7) 253-7973 Bracket (15) 8T-4121 Hard Washer (16) 8T-4133 Nuts (18) 8T-4196 Bolt
Install 253-7973 Bracket (7) by using two 8T-4196 Bolts (18), four 8T-4121 Hard Washers (15), and two 8T-4133 Nuts (16). Refer to Illustration 6.Note: The left side of bracket (7) will be bolted to the engine block while the right side of the bracket will be free.
Illustration 7 g01879515
(3) 108-8625 Exhaust Coupling
Install one end of 108-8625 Exhaust Coupling (3) and 6N-0009 Metal Seal Ring (1) (not shown) into the end of the turbocharger. Refer to Illustration 7.
Illustration 8 g01879516
(2) 7E-3870 Muffler Clamp (3) 108-8625 Exhaust Coupling (8) 277-4717 Exhaust Elbow (15) 8T-4121 Hard Washer (17) 8T-4195 Bolt
Install 277-4717 Exhaust Elbow (8) by inserting the exhaust elbow into the other end of 108-8625 Exhaust Coupling (3). Tighten the exhaust elbow to the engine block by using four 8T-4195 Bolts (17) and four 8T-4121 Hard Washers (15). Tighten the four bolts to a torque of 7.5 N m (66 lb in). Refer to Illustration 8.
Apply 4C-5597 Anti-Seize Compound to the treads of 7E-3870 Muffler Clamp (2) and place the muffler clamp on exhaust coupling (3). Leave the muffler clamp positioned loosely. Refer to Illustration 8.
Illustration 9 g01879521
(5) 253-4495 Clamp As (6) 253-7967 Bracket (7) 253-7973 Bracket (15) 8T-4121 Hard Washer (16) 8T-4133 Nuts (18) 8T-4196 Bolt
Install one 253-4495 Clamp Assembly (5) to 253-7967 Bracket (6). Use two 8T-4196 Bolts (18), four 8T-4121 Hard Washers (15), and two 8T-4133 Nuts (16) to tighten clamp assembly (5) to bracket (6). Refer to Illustration 9.
Install the other 253-4495 Clamp Assembly (5) to 253-7973 Bracket (7). Use two 8T-4196 Bolts (18), four 8T-4121 Hard Washers (15), and two 8T-4133 Nuts (16) to tighten clamp assembly (5) to bracket (7). Refer to Illustration 9.
Illustration 10 g01879798
(4) 253-4346 Diesel Particulate Filter Gp (5) 253-4495 Clamp As (8) 277-4717 Exhaust Elbow
Install 253-4346 Diesel Particulate Filter Gp (4) by placing the diesel particulate filter group onto clamp assemblies (5) and inserting the inlet tube over the exposed end of exhaust elbow (8). The weight of the diesel particulate filter group is approximately 60 kg (132 lb). Refer to Illustration 10.
Illustration 11 g01879814
(5) 253-4495 Clamp As (9) 277-4718 Clamp As (10) 3B-4508 Lockwasher (12) 5P-8245 Hard Washer (13) 6V-8336 Bolt (14) 6V-8149 Nut
Position 277-4718 Clamp Assembly (9) over clamp assembly (5).