101601-5580 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015580

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-5580 1016015580

Service parts 101601-5580 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-3580

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0580

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7690

11. Nozzle and Holder 23600-2060A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105030-4170

14. NOZZLE 105015-7580

15. NOZZLE SET

Include in #1:

101601-5580 as INJECTION-PUMP ASSEMBLY

104303-2390 as _

Cross reference number

ZEXEL 101601-5580 1016015580

Zexel num

Bosch num

Firm num

Name

101601-5580

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 900 900 900

Average injection quantity mm3/st. 48.9 46.9 50.9

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 H

Rack position 8.3+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 7 5.5 8.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 48.9 47.9 49.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 51.3 47.3 55.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 35.9 31.9 39.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1(9.4)

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 52.1 48.1 56.1

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position (R1+0.45 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 31.4 27.4 35.4

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 111 101 121

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1330--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1280

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4.5 4.2 4.8

Load 4/4

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
----------
T1=E04
----------

Speed control lever angle

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

----------
a=37deg+-5deg b=39deg+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)At speed = aa, temporarily set the stopper screw so that the rack = bb. (2)Further turn the stop screw cc (dd turns) in the stop direction and set (rack position = ee). (3)After setting, apply red paint.
----------
aa=1750r/min bb=5.2mm cc=1.5mm dd=1.5 ee=(3.2)mm
----------
a=20deg+-5deg b=29.5deg+-5deg

Timing setting

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

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