101691-3030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016913030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101691-3030 1016913030

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Service parts 101691-3030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3970

3. GOVERNOR 105921-6330

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS 105614-3550

6. COUPLING PLATE 105661-0830

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4110

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105048-3060

14. NOZZLE

105017-0090

15. NOZZLE SET

Include in #1:

101691-3030 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-3840 as _

104745-3841

Cross reference number

ZEXEL 101691-3030 1016913030

Zexel num

Bosch num

Firm num

Name

101691-3030

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 -

Rack position 11.5

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 69 67.4 70.6

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 -

Rack position 9.9+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 69 68 70

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_04

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 96 86 106

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 1500 1500 1500

Rack position R1-0.4

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 1500 1500 1500

Rack position R1(11.5)

Boost pressure kPa 18.7 14.7 22.7

Boost pressure mmHg 140 110 170

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: none (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
BCL=0.4+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=(40deg)+-3deg b=40deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

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

----------
a=(30deg)

Information:

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9N2649 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)9N0678 Flywheel Group
4W6730 FlywheelMake reference to Flywheel Runout for correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)6N1299 Flywheel Group
6N1301 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)4W7370 Flywheel Group
4W7186 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)(2) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N (200 20 lb ft)(3) Bore in bushing ... 52.007 0.013 mm (2.0475 .0005 in)(4) Diameter of bushing ... 72.022 0.015 mm (2.8355 .0006 in) Bore in flywheel ... 71.971 0.015 mm (2.8335 .0006 in)