101601-5140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015140

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-5140 1016015140

Service parts 101601-5140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-1540

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0290

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4370

11. Nozzle and Holder 236001800A

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

13. NOZZLE-HOLDER 105041-5080

14. NOZZLE 105015-5640

15. NOZZLE SET

Include in #1:

101601-5140 as INJECTION-PUMP ASSEMBLY

106682-4920 as _

Cross reference number

ZEXEL 101601-5140 1016015140

Zexel num

Bosch num

Firm num

Name

101601-5140

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 131424-5720

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 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 9.4

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 62.6 60.6 64.6

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 8.6+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 9 7.5 10.5

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(9.4)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 62.6 61.6 63.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+0.05 )

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 56 54 58

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1200+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 4 3.7 4.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=B67
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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----------
a=34deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the normal set bolt. (2)Engine normal (3)Engine stop
----------

----------
a=(12deg) b=(22deg)+-5deg c=35deg+-5deg d=40deg+-5deg

0000001501 LEVER

(A) Pump's normal lever (B) Engine's normal lever (C) Engine stop (D) Pump stop (E) Stop direction (perpendicular) (F) Normal set bolt (g) rack limit Stop lever angle and engine's normal setting procedures (1)After completing adjustment, confirm that the pump's normal lever angle and the pump's stop lever angle are within the specifications in the figure above. (2)Before setting the rack limit, screw in the normal set bolt, return it 1 turn from point I and then fix the normal set bolt using the locknut. (engine normal) (3)With the lever at idle and N = Na, pull the stop lever in the stop direction so that the rack position is the non-injection position. Measure the angle at this time. (Engine stop) (4)Set the rack limit. (Point I adjustment)
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Na=250r/min ra=40mm a=(12deg) b=(22deg)+-5deg c=35deg+-5deg d=40deg+-5deg
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Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(70deg)