101603-9140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9140 1016039140

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Service parts 101603-9140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3290

3. GOVERNOR 105492-0230

4. SUPPLY PUMP 105220-5200

5. AUTOM. ADVANCE MECHANIS 105643-0250

6. COUPLING PLATE 105661-0350

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5440

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3522

14. NOZZLE 105015-7100

15. NOZZLE SET

Include in #1:

101401-4281 as _

101603-9140 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-9140 1016039140

Zexel num

Bosch num

Firm num

Name

101603-9140
101603-9141

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(11.1)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 60 58 62

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. 10.1 8.6 11.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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 1500

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Deliver without the torque control spring operating. (4)Excess fuel setting for starting: SXL (5)Damper spring setting: DL
----------
RT=1 TH=1.9mm SXL=(R1+0.1)+0.2mm DL=8.7-0.5mm
----------

Speed control lever angle

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

----------
a=(9deg)+-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=(19deg)+-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:

7G7889 Alternator
Voltage rating ... 12VPolarity ... Neg GrndRotation ... Either DirectionSpeed for testing (rpm) ... 2600 to 6500Output (cold) ... 28 A @ 14VOutput (cold) ... 62A @ 14VRated output (hot) at max speed ... 60 AField current at rated voltage and 27°C (80°F) ... 7 to 8APositive output terminal torque ... 6.2 to 8.0 N m (55 to 71 lb in)(1) Ground terminal torque ... 1.7 to 2.9 N m (15 to 26 lb in)(2) Shaft nut torque ... 95 to 109 N m (70 to 80 lb ft)Regulator (9G5235-Inside Alternator)
Voltage setting ... No AdjustmentPermissible voltage range ... 13 to 15V3T6352 Alternator
Voltage rating ... 24VPolarity ... Neg GrndRotation ... Either DirectionSpeed for testing (rpm) ... 2600 to 6500Output (cold) ... 15A @ 28VOutput (cold) ... 35A @ 28VRated output (hot) at max speed ... 35AField current at rated voltage and 27°C (80°F) ... 2.5 to 3.2APositive output terminal torque ... 6.2 to 8.0 N m (55 to 71 lb in)(1) Ground terminal torque ... 1.7 to 2.9 N m (15 to 26 lb in)(2) Shaft nut torque ... 95 to 109 N m (70 to 80 lb ft)Regulator (3T6354 - Inside alternator)
Voltage setting ... No AdjustmentPermissible voltage range ... 26 to 30 V 9G6079 & 6T1194 Alternators
Voltage rating ... 12VPolarity ... Neg GrndRotation ... Either DirectionOutput at 2000 rpm (cold) ... 30AOutput at 5000 rpm (cold) ... 57ARated output (hot) ... 61A(1) Torque for stud nut for battery connection ... 2.8 to 4.5 N m (25 to 40 lb in)(2) Torque for pulley nut ... 100 7 N m (75 5 lb ft)Voltage Regulator (3S8828) is internally mounted and is not adjustable.9G6081 & 6T1196 Alternators
Polarity ... Neg GrndRotation ... Either DirectionOutput at 2600 rpm (cold) ... 25AOutput at 7000 rpm (cold) ... 41ARated output (hot) ... 40A(1) Torque for stud nut for battery connection ... 2.8 to 4.5 N m (25 to 40 lb in)(2) Torque for pulley nut ... 100 7 N m (75 5 lb ft)Voltage Regulator (3T6354) is internally mounted and not adjustable.Bosch Alternators
7N9720 Alternator
Voltage rating ... 24VPolarity ... Neg GrndRotation ... Either DirectionSpeed for testing (rpm) ... 4000Output (cold) ... 47AOutput (hot) ... 37AField Current at 28V and 25° C (77°F) ... 1.8A(1) Torque for pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for output terminal B+ ... 7.5 to 10 N m (5.5 to 7.0 lb ft)Torque for ground terminal ... 2.1 to 2.8 N m (19 to 25 in lb)Regulator Number ... 9G7567 9W3043 Alternator
Voltage rating ... 24VPolarity ... Neg GrndRotation ... ClockwiseSpeed for testing (rpm) ... 5000Output (cold) ... 40AOutput (hot) ... 52AField current at 28V and 25°C (77°F) ... 2.9A(1) Torque for pulley nut ... 50 5 N m (37 4 lb ft)(2) Torque for output terminal B+ ... 7.8 0.8 N m (70 7 lb in)(3) Torque for field D+ terminal nut ... 1.70 0.25 N m (15 2 lb