101691-3031 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016913031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101691-3031 1016913031

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Cross reference number

ZEXEL 101691-3031 1016913031

Zexel num

Bosch num

Firm num

Name

101691-3031

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 12.6

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 81 79.4 82.6

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 10+-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(12.6)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 81 80 82

Basic *

Fixing the lever *

Boost pressure kPa 47.3 47.3

Boost pressure mmHg 355 355

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 R1-1.15

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(12.6)

Boost pressure kPa 36.7 32.7 40.7

Boost pressure mmHg 275 245 305

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: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=H47 BCL=1.15+-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=37deg+-5deg b=38deg+-3deg

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:

5N5692 24V 45A
Load the battery with a carbon pile (6V4930 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 6500Output voltage ... 27.5 1.0VOutput (cold) ... 45A(1) Torque for the ground terminal nut ... 2.3 0.6 N m (21 5 lb in)(2) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(3) Torque for the output terminal nut ... 7.1 0.9 N m (64 8 lb in)3T6353 Regulator (Inside Alternator)
Voltage setting ... No adjustmentPermissible voltage range ... 26 to 30VDelco-Remy (27SI)
9L5938 12V 65A
Rotation ... Either DirectionPolarity ... negative groundRated output (cold): 2000 rpm ... 46A5000 rpm ... 58ARated output (hot) ... 65AOutput voltage ... 14.0 .5VField current at 12V and 27°C (80°F) ... 5.2 to 5.8A(1) Torque for pulley nut ... 100 7 N m (75 5 lb ft)(2) Terminal torques: Torque for battery connection nut ... 3.7 0.8 N m (32.5 7.5 lb in)Torque for ground connection nut ... 9.0 3.0 N m (80 27 lb in)3T7070 12V 65A
Rotation ... Either DirectionPolarity ... negative groundRated output (cold): 2000 rpm ... 52A5000 rpm ... 72ARated output (hot) ... 80AOutput voltage ... 14.0 .5VField current at 12V and 27°C (80°F) ... 5.2 to 5.8A(1) Torque for pulley nut ... 100 7 N m (75 5 lb ft)(2) Terminal torques: Torque for battery connection nut ... 3.7 0.8 N m (32.5 7.5 lb in)Torque for ground connection nut ... 9.0 3.0 N m (80 27 lb in)9L6774 Regulator (Inside Alternator)
Voltage rating ... 12VVoltage setting ... No AdjustmentVoltage range ... 14.0 .5VDelco-Remy (30SI)
4N3986 24V 60A
Load the battery with a carbon pile (6V4930 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 6500Output voltage ... 27.5 1.0VOutput (cold) ... 60A(1) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(2) Torque for the output terminal nut ... 7.1 0.9 N m (64 8 lb in)3T6354 Regulator (Inside Alternator)
Voltage setting range ... 26 to 30VRated voltage ... 28V(A) Adjust the voltage with the four-position cap. Lo ... Low2 ... Medium Low3 ... Medium HighHi ... High