101609-3060 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093060

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3060 1016093060

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Cross reference number

ZEXEL 101609-3060 1016093060

Zexel num

Bosch num

Firm num

Name

101609-3060

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 131424-1520

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)
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 3.2 3.15 3.25

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 10

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 79 78 80

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.3+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 15+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 125 145

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Rack difference between N = N1 and N = N2
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K=12 RAL=15+0.2mm N1=1150r/min N2=800r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
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aa=80mm
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a=36deg+-5deg b=18deg+-3deg c=32deg+-3deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
----------

----------
a=58deg+-3deg b=2deg+-30min

Information:

Introduction
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a