101681-9520 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016819520

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101681-9520 1016819520

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Service parts 101681-9520 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101068-3780

3. GOVERNOR 105462-0560

4. SUPPLY PUMP 105210-4620

5. AUTOM. ADVANCE MECHANIS 105612-3290

6. COUPLING PLATE 105661-0450

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101681-9520 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-3230 as _

104745-3231

104745-3232

Cross reference number

ZEXEL 101681-9520 1016819520

Zexel num

Bosch num

Firm num

Name

101681-9520

INJECTION-PUMP ASSEMBLY
6105Q *

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

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 2.2 2.15 2.25

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 1400 1400 1400

Average injection quantity mm3/st. 65 63 67

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_04

Pump speed r/min 1400

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)RACK LIMIT: RAL (3)Rack difference between N = N1 and N = N2
----------
DL=5.4-0.5mm RAL=16+0.2mm N1=1400r/min N2=800r/min
----------

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa
----------
aa=30mm
----------
a=25deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

Illustration 1 g06022453
Typical example
(1) Existing fuel injection pump stop solenoid with red colored connection
(2) New fuel injection pump stop solenoid with cream colored connectionThere have been some isolated instances of issues with the existing fuel injection pump stop solenoid (1). The issues with the fuel injection pump stop solenoid have caused issues with starting the engine and fuel leaks.A new fuel injection pump stop solenoid (2) has been introduced. The improved fuel injection pump stop solenoid will offer better reliability and extended service life.The part number for the fuel injection pump stop solenoid has not changed.Follow step 1 through to step 7 for the correct procedure to replace the fuel injection pump stop solenoid.
Turn the battery disconnect switch to the OFF position.
Disconnect the electrical connection from the fuel injection pump stop solenoid.
Remove the existing fuel injection pump stop solenoid.
Install the new fuel injection pump stop solenoid. Tighten the fuel injection pump stop solenoid to a torque of 15 N m (133 lb in).
Remove the protective cap.
Connect the electrical connection to the fuel injection pump stop solenoid.
Turn the battery disconnect switch to the ON position.