101691-6200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016916200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101691-6200 1016916200

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Buy INJECTION-PUMP ASSEMBLY 101691-6200 zexel genuine, new aftermarket engine parts with delivery

Service parts 101691-6200 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-9500

3. GOVERNOR 105402-2430

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-0730

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4862

11. Nozzle and Holder ME080371

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105048-3501

14. NOZZLE

105017-0850

15. NOZZLE SET

Include in #1:

101691-6200 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-8240 as _

104745-8241

Cross reference number

ZEXEL 101691-6200 1016916200

Zexel num

Bosch num

Firm num

Name

101691-6200

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 131424-5620

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 3.5 3.45 3.55

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 9.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.8 53.8 55.8

Max. variation between cylinders % 0 -2.5 2.5

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. 7.5 6.2 8.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 66 66 71

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1000++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1000.

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Supplied with torque spring not set. (3)RACK LIMIT (4)Set at delivery (5)Rack difference between N = N1 and N = N2
----------
K=13 N1=1200r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At delivery
----------

----------
a=6deg+-5deg b=23deg+-5deg c=(2deg)

Stop lever angle

N:Pump normal S:Stop the pump. (1)At delivery
----------

----------
a=43deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(130deg)

Information:

Start By:a. disassemble governorb. remove fuel injection pumps
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove cover (1) and gasket. 2. Remove rack (2).
If the original lifters are to be installed in the fuel injection pump housing, put identification marks on them as to their location in the housing.
3. Remove lifters (3). 4. Put the fuel injection pump housing on end on blocks. Use tool (A) to remove snap ring (4). 5. Use a soft hammer to push the camshaft toward the governor end of the fuel injection pump housing to loosen washer (5). Remove washer (5). 6. Remove camshaft (6). 7. Remove bearings (7) from the drive end of the fuel injection pump housing. 8. Remove bearings (8) from the governor end of the fuel injection pump housing.Assemble Fuel Injection Pump Housing
Be sure all oil passages are clear, and put clean oil on all parts before assembly. 1. Use tooling (B) to install bearing (10) in the governor end of the fuel injection pump housing with junction (joint) (11) toward the top of the fuel injection pump housing. Install the bearing so it is 0.25 0.20 mm (0.10 0.008 in) below the surface of the housing.2. Use tooling (B) to install bearing (9) in the governor end of the fuel injection pump housing so it is 7.16 0.13 mm (0.282 0.005 in) below the surface of the housing. 3. Use tooling (B) to install bearing (12) in the drive end of the fuel injection pump housing with the junction (joint) in the bearing toward the top of the fuel injection pump housing. Install the bearing so it is 1.00 0.25 mm (9.039 0.010 in) below the surface of the housing. 4. Install plate (13) of tooling (C) on the drive end of the fuel injection pump housing to install the bearing for the rack. Use clean grease to hold the new rack bearing on driver (14) of tooling (C). Install the driver and bearing in plate (13) with the groove in the driver in alignment with the pin in the plate and use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against plate (13).5. Remove tooling (C) from the fuel injection pump housing. The rack bearing must be installed so it is 0.25 0.25 mm (0.010 0.010 in) below the surface of the housing. 6. Install camshaft (6).7. Put the fuel injection pump housing on end, and place a block under the camshaft. 8. Put washer (5) over the end of the camshaft and use tooling (B) and a spacer (15) that has an inside diameter of 38.1 mm (1.5 in) and a length of 31.75 mm (1.25 in) to push the washer against its seat on the camshaft. Camshaft must have 0.285 0.235 mm (0.0112 0.0093 in) end play