101601-5140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015140


101601-5140 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101601-5140
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B67
----------

Speed control lever angle

Test data 101601-5140
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-3deg b=34deg+-5deg

Stop lever angle

Test data 101601-5140
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

Test data 101601-5140
(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)
----------
Na=250r/min ra=40mm a=(12deg) b=(22deg)+-5deg c=35deg+-5deg d=40deg+-5deg
----------

Timing setting

Test data 101601-5140
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)




Have questions with 101601-5140?





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