101691-9622 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919622


 

Information injection-pump assembly

ZEXEL 101691-9622 1016919622
101691-9622 INJECTION-PUMP ASSEMBLY
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Service parts 101691-9622 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101069-3650
3. GOVERNOR 105921-2052
4. SUPPLY PUMP 105220-5690
5. AUTOM. ADVANCE MECHANIS 105614-3311
6. COUPLING PLATE 105661-0631
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6970
11. Nozzle and Holder 16600-95011
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105031-4620
14. NOZZLE 105015-6600
15. NOZZLE SET

Include in #1:

101691-9622 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101691-9622 1016919622


Zexel num
Bosch num
Firm num
Name
101691-9622 
 
   
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 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   1-4-2-6- 3-5
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   -
Rack position   13.6
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   106.4 104.8 108
Max. variation between cylinders %   0 -3.5 3.5
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   275 275 275
Average injection quantity mm3/st.   9 7.2 10.8
Max. variation between cylinders %   0 -10 10
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(13.6)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   106.4 105.4 107.4
Basic   *
Fixing the lever   *
Boost pressure kPa   29.3 29.3 29.3
Boost pressure mmHg   220 220
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   96.7 93.5 99.9
Fixing the lever   *
Boost pressure kPa   29.3 29.3 29.3
Boost pressure mmHg   220 220
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(12.7)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   62.9 61.9 63.9
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.8+-0. 5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   80 80 100
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   400 400 400
Rack position   R2(12.7)
Boost pressure kPa   4 2.7 5.3
Boost pressure mmHg   30 20 40
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R1-0.5
Boost pressure kPa   9.3 8 10.6
Boost pressure mmHg   70 60 80
Boost compensator adjustment_03
Pump speed r/min   400 400 400
Rack position   R1+0.1
Boost pressure kPa   16 16 16
Boost pressure mmHg   120 120 120
Timer adjustment
Pump speed r/min   920--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   870
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101691-9622
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B36
----------

Speed control lever angle

Test data 101691-9622
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26.5deg+-5deg b=43deg+-3deg

Stop lever angle

Test data 101691-9622
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

Test data 101691-9622
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Storage Procedure
1. Clean the outside of the engine and repaint areas that have paint damage with a good quality paint.2. Remove the batteries and use them in some other place or put them in storage where they can be checked and electrically charged again when needed. If the batteries are not removed, wash the tops. Put an electrical charge to the battery to a specific gravity of 1.275. Disconnect the battery terminals. Put a plastic cover over the battery.3. Loosen all fan, alternator belts, etc. Attach a tag to indicate what work has been done.4. Put a waterproof cover over engines with enclosures stored outdoors. Make the cover tight, but loose enough to allow air to circulate around the engine to prevent damage to exposed metal parts from condensation. Remove the waterproof cover every two or three months and check the engine for corrosion. If the engine has signs of corrosion at the check period, follow the protection procedure again. To operate the engine, it is not necessary to remove the preservative oil mixture. If a compartment under protection of VCI vapors is opened, put more VCI mixture in to make up for the vapor loss. Install all covers and/or put tape over all openings, air intake, exhaust openings, flywheel housing, crankcase breathers, dipstick tubes, etc. Make sure all covers are air tight and weatherproof. Use a waterproof, weather resistant tape.5. Put lubricant on all points given in the Lubrication and Maintenance Chart.6. Put a heavy amount of multipurpose grease on all outside parts that move; rod threads, ball joints, linkage, etc.7. Oil and oil filter elements used less than 50 hours in the engine do not need to be changed. (Otherwise, change the oil, filling the engine to the "add oil" mark on the dipstick.) Add 3% to 4% of VCI oil per engine volume. If the engine is drained, install a mixture of 50% VCI oil and 50% engine oil in the crankcase and in all lubricating oil compartments at the rate of one part VCI oil mixture per fifteen parts of compartment capacity at full level. If possible, operate the engine three to five minutes. Put tape over all openings to seal VCI vapors in the engine. If necessary, drain some lubricant to add to the mixture.8. Remove any dirt from the air cleaner. Check all seals and gaskets.9. Remove the air filter elements. Turn the engine at cranking speed with throttle control in fuel OFF position, remove pressure plug for boost pressure and use a sprayer to add a mixture of 50% VCI oil and 50% engine oil. Minimum application rate is 5.5 milliliters per liter (3 oz. per

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