101609-3210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3210 1016093210

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Service parts 101609-3210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8860

3. GOVERNOR 105419-2020

4. SUPPLY PUMP 105210-6260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6260

11. Nozzle and Holder 6221-13-3500

12. Open Pre:MPa(Kqf/cm2) 23.0{235}

13. NOZZLE-HOLDER 105048-3560

14. NOZZLE 105017-1960

15. NOZZLE SET

Include in #1:

101609-3210 as INJECTION-PUMP ASSEMBLY

Include in #2:

104257-3032 as _

Cross reference number

ZEXEL 101609-3210 1016093210

Zexel num

Bosch num

Firm num

Name

101609-3210

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 131424-3420

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 3.6 3.55 3.65

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 9.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 124 123 125

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 13 11.8 14.2

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 205 195 215

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Stopper bolt setting (3)Set the pump speed at bb (at delivery)
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=2deg+-5deg c=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=6.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(50deg)

Information:

3T6352 Alternator 24V 35A (Delco-Remy Number 1117647)
Load battery with a carbon pile (6V4930 Battery Load Tester) to get maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionOutput voltage ... 27.5 1.0VSpeed for testing (rpm) ... 5000Output (hot) ... 35APositive 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 110 N m (70 to 80 lb ft) 3T6354 Regulator (Delco-Remy Number 1116405) - Inside Alternator. For use with 3T6352 Alternators
Voltage setting ... No AdjustmentPermissible voltage range ... 26 to 30VBosch
7N9720 Alternator 24V 35A (Bosch Number 0-122-469-001)
Load battery with a carbon pile (6V4930 Battery Load Tester) to get maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (hot) ... 35A(1) Torque for pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for output terminal B+ ... 17 to 22 N m (13 to 16 lb ft)Torque for ground terminal ... 2.1 to 2.8 N m (19 to 25 lb in) 9G7567 Regulator (Bosch Number 1-197-011-000)-under alternator cover. For use with 7N9720 Alternators.
Voltage setting ... No AdjustmentPermissible voltage range ... 26.7 to 28.3VNippondenso
9G4574 24V 35A (Nippondenso Number 100211-0860)
Load battery with a carbon pile (6V4930 Battery Load Tester) to get maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (hot) ... 35A(1) Torque for pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for output terminal ... 22 to 37 N m (16 to 27 lb ft)(3) Torque for ground terminal ... 3.4 to 5.4 N m (31 to 49 lb in) 7T2798 Regulator (Nippondenso Number 126000-0380) - Inside Alternator. For use with 9G4574 Alternators.
Voltage setting ... No adjustmentPermissible voltage range ... 26.5 to 28.5V