101603-9130 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039130

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9130 1016039130

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Cross reference number

ZEXEL 101603-9130 1016039130

Zexel num

Bosch num

Firm num

Name

101603-9130
101603-9132

INJECTION-PUMP ASSEMBLY
6110 *

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)
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
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 A

Rack position R1(10.9)

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 57 55 59

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 9.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8.8 7.3 10.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 73

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3.2 2.7 3.7

Timer adjustment_04

Pump speed r/min 1450

Advance angle deg. 6 5.5 6.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 6.5 6.5 6.5

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
----------
RT=1 TH=2.6mm SXL=(R1+0.2)+0.2mm DL=6.5-0.5mm
----------

Speed control lever angle

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

----------
a=(20deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=55mm
----------
a=5.5deg+-5deg b=(25deg)+-3deg

Stop lever angle

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

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

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

(1) Diameter of the valve seat insert ... 54.610 0.013 mm (2.1500 .0005 in) Bore in head for valve seat insert ... 54.534 0.013 mm (2.1470 .0005 in)(2) Depth of bore in head for valve seat insert ... 11.23 0.05 mm (.442 .002 in)(3) Maximum permissible width of the face of the valve seat insert ... 3.05 mm (.120 in)(4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... 1.73 mm (.068 in)Minimum permissible (valve closed) ... 0.91 mm (.036 in)(5) Angle of the face of the valve seat insert ... 30 1/2 1/2°(6) Outside diameter of the face of the valve seat insert ... 52.23 0.13 mm (2.045 .005 in) Maximum permissible ... 52.45 mm (2.065 in)(7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°Intake Valve (without valve seat insert)
(1) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... 1.73 mm (.068 in)Minimum permissible (valve closed) ... 0.91 mm (.036 in)(2) Maximum permissible width of the face of the valve seat ... 3.05 mm (.120 in)(3) Outside diameter of the valve seat ... 52.23 0.13 mm (2.045 .005 in) Maximum permissible ... 52.45 mm (2.065 in)(4) Angle of the face of the valve seat ... 30 1/2 1/2°(5) Diameter of the bore ... 54.61 mm (2.150 in)(6) Maximum permissible depth of the bore to make the face of the valve seat smaller ... 4.32 mm (.170 in)Exhaust Valve
(1) Depth of bore in head for valve seat insert ... 11.23 0.13 mm (.442 .005 in)(2) Diameter of valve seat insert ... 48.565 0.013 mm (1.9120 .0005 in) Bore in head for valve seat insert ... 48.489 0.013 mm (1.9090 .0005 in)(3) Maximum permissible width of the face of the valve seat insert ... 2.67 mm (.105 in)(4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... 2.16 mm (.085 in)Minimum permissible (valve closed) ... 1.27 mm (.050 in)(5) Angle of the face of the valve seat insert ... 45 1/2 1/2°(6) Outside diameter of the face of the valve seat insert ... 44.07 0.13 mm (1.735 .005 in) Maximum permissible ... 44.70 mm (1.760 in)(7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°