101602-1560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016021560


101602-1560 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101602-1560 1016021560

Service parts 101602-1560 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-8040
3. GOVERNOR 105411-1780
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156637-7220
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4850
11. Nozzle and Holder ME078538
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3350
14. NOZZLE 105025-1870
15. NOZZLE SET

Include in #1:

101602-1560 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101602-1560 1016021560


Zexel num
Bosch num
Firm num
Name
101602-1560 
 
   
INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SEJ967d}
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4.5 4.45 4.55
Beginning of injection position
Governor 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   9.6
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   122 118.5 125.5
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Boost pressure kPa   53.3 53.3
Boost pressure mmHg   400 400
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.6+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   10.5 9 12
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   R1-0.75
Boost pressure kPa   28 25.3 30.7
Boost pressure mmHg   210 190 230
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   R1(9.6)
Boost pressure kPa   40 33.3 46.7
Boost pressure mmHg   300 250 350

Test data Ex:

Governor adjustment

Test data 101602-1560
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Rack difference between N = N1 and N = N2 (5)Set idle sub-spring
----------
K=16 BCL=0.75+-0.1mm N1=750r/min N2=250r/min
----------

Speed control lever angle

Test data 101602-1560
F:Full speed I:Idle (1)Stopper bolt setting (2)Pump speed = aa (3)Pump speed = bb
----------
aa=750r/min bb=900r/min
----------
a=1deg+-5deg b=22deg+-5deg c=6deg+-5deg

Stop lever angle

Test data 101602-1560
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

Timing setting

Test data 101602-1560
(1)Pump vertical direction (2)Position of coupling's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(1deg)




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