101607-1970 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016071970

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-1970 1016071970

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Service parts 101607-1970 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9540

3. GOVERNOR 105921-5800

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105672-0280

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4901

11. Nozzle and Holder ME086584

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

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE 105017-0890

15. NOZZLE SET

Include in #1:

101402-7400 as _

101607-1970 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101607-1970 1016071970

Zexel num

Bosch num

Firm num

Name

101607-1970

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 131424-6220

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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 -

Rack position 11.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.1 58.5 61.7

Max. variation between cylinders % 0 -2.5 2.5

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

Average injection quantity mm3/st. 12.2 10.9 13.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.1 59.1 61.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.7

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 72.6 68.6 76.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.55

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 53.3 49.3 57.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 73 78

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 1 0.5 1.5

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
----------
T1=G78
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=43deg+-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. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee or less (non-injection rack position). (4)- (5)Rack position corresponding to ff (6)Free (at delivery)
----------
aa=40mm bb=1600r/min cc=6.5-0.5mm dd=275r/min ee=(8)mm ff=16mm
----------
a=25deg+-5deg b=15deg+-5deg c=33deg+-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=9deg
----------
a=(0deg)

Information:

Cooling System Diagram
Illustration 18 g00594718
Touch the icon for the cooling system on the navigation bar in order to view the window. The window displays the cooling system parameters. The window also displays a system diagram.Touch the gauge in the upper right hand corner in order to see a real time data for the cooling system.Real Time Data for the Cooling System
Illustration 19 g00562789
"Cooling System" Screen
Illustration 20 g00562791
SymbolsTouch the gauge in the upper right hand corner in order to see a real time data for the cooling system. The window has gauges and a trend chart in real time. An hour of real time data is displayed.Touch the gauge in order to see the trends. The trend chart only shows one parameter at one time.Touch the after cooler and oil cooler water inlet temperature gauge in order to see the trend on the graph.Touch the icon in the upper right corner of the window in order to return to the cooling system diagram.The critical limits are shown with a yellow mark on the gauge. Engine shutdown conditions are shown with a red mark on the gauge.Exhaust
Exhaust Port Temperatures
Illustration 21 g00562793
Touch the exhaust icon on the navigation bar in order to view the window for the exhaust port temperature. The exhaust port temperatures are represented by a bar graph. The actual exhaust temperature is shown with a blue mark. The normal operating temperature range for each port is shown with a green mark. The variation of the critical limits are shown with yellow marks. The critical limit is shown with a yellow mark. The average port temperature is shown with a purple mark. Touch the "Deviation" button in order to view the exhaust port temperature deviation.Touch the trend icon in order to view the stack temperatures and the manifold temperatures as well as trends in real time. Exhaust Port Temperature Deviation
Illustration 22 g00562798
Touch the "Deviation" button on the "Exhaust Port Temperatures" window in order to view the Exhaust Port Temperature Deviation. The window shows the deviation from the average for each port temperature. The yellow marks are the maximum temperature deviation. This is the deviation that is allowed above the average temperature and below the average temperature.Touch the button with the arrows and the bar graph in order to return to the "Exhaust Port Temperatures" window.Exhaust Stack and Manifold
Illustration 23 g00562800
Touch the trend icon on the "Exhaust Port Temperatures" window in order to view the "Exhaust Manifold and Stack Temperatures" window. The actual exhaust manifold temperature and stack temperature will be a blue color. The variation of the normal operating temperature for the exhaust manifold and the stack temperature is shown as a green color. The variation of the critical limits are shown with yellow marks. The critical limit is shown with a yellow mark. The average port temperature is shown with a purple mark. Touch the trends icon in order to view the stack temperatures and manifold temperatures. This button also shows trends in real time.Touch the arrow icon in order to return to the