101607-1002 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016071002

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-1002 1016071002

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Service parts 101607-1002 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8350

3. GOVERNOR 105931-7910

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-0760

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7140

11. Nozzle and Holder ME076615

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105030-4290

14. NOZZLE

105015-8480

15. NOZZLE SET

Include in #1:

101402-7270 as _

101607-1002 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101607-1002 1016071002

Zexel num

Bosch num

Firm num

Name

101607-1002

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 105780-8140

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 3.2 3.15 3.25

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 -

Rack position 11.6

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 72.5 70.3 74.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 8.3 7.1 9.5

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 72.5 71.5 73.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 79.5 75.5 83.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.65

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 71.5 67.5 75.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 14.8+-0. 2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 100 140

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_03

Pump speed r/min 1380

Advance angle deg. 5 4.5 5.5

Remarks
Finish

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: RAL
----------
T1=F14 RAL=14.8+-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(40deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
----------
aa=50mm bb=1400r/min cc=6.9-0.5mm
----------
a=25deg+-5deg b=25deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

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=11deg
----------
a=(0deg)

Information:

Typical Example(1) Torque for terminal nuts: Large terminal nuts ... 30 3 N m (22 2 lb ft)Small terminal nuts ... 2.25 0.25 N m (20 2 lb in)(2) Tighten the screws that hold the nose housing to the lever housing to a torque of ... 20 2 N m (15 1 lb ft)Clearance between the pinion and housing (pinion clearance) ... 8.3 to 9.9 mm (.33 to .39 in)Rotation as seen from drive end ... clockwiseNo load conditions: Speed (rpm) ... 7643 1683Current amps ... 60 to 75Voltage ... 238C3595, 6V4214 12V
(1) Torque for terminal nuts: Large terminal nuts ... 30 3 N m (22 2 lb ft)Small terminal nuts ... 2.25 0.25 N m (20 2 lb in)(2) Tighten the screws that hold the nose housing to the lever housing to a torque of ... 20 2 N m (15 1 lb ft)Clearance between the pinion and housing (pinion clearance) ... 8.3 to 9.9 mm (.33 to .39 in)Rotation as seen from drive end ... clockwiseNo load conditions: Speed (rpm) ... 6900 1800Current amps ... 100 to 155Voltage ... 113T2371 24V
Rotation as seen from the drive end ... clockwiseMinimum (no load) speed (rpm) ... 5500Maximum current consumption (draw) (no load) ... 140A(1) Tighten the large terminal nuts to a torque of ... 27 to 34 N m (20 to 25 lb ft) Tighten the small terminal nuts to a torque of ... 2.25 0.25 N m (20 2 lb in)(2) Service limit of brushes ... 17.5 mm (.69 in)(3) Service limit of commutator diameter ... 48 mm (1.9 in)Pinion to ring gear clearance ... 1.5 to 5.5 mm (.06 to .22 in)9X4454 24V
Rotation as seen from the drive end ... clockwiseMinimum (no load) speed (rpm) ... 3300Maximum current consumption (draw) (no load) ... 80A(1) Tighten the large terminal nuts to a torque of ... 27 to 34 N m (20 to 25 lb ft) Tighten the small terminal nuts to a torque of ... 2.25 0.25 N m (20 2 lb in)(2) Service limit of brushes ... 17 mm (.67 in)(3) Service limit of commutator diameter ... 46 mm (1.81 in)