101681-9580 ZEXEL Calibration Data 1016819580


 

Information

ZEXEL 101681-9580 1016819580
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Service parts 101681-9580 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101068-8050
3. GOVERNOR 105490-5570
4. SUPPLY PUMP 105220-4080
5. AUTOM. ADVANCE MECHANIS 105622-1170
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4582
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105031-3952
14. NOZZLE 105015-4130
15. NOZZLE SET

Include in #1:

101681-9580 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101681-9580 1016819580


Zexel num
Bosch num
Firm num
Name
101681-9580 
 
   

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   1-5-3-6- 2-4
Pre-stroke mm   2.2 2.15 2.25
Beginning of injection position
Drive 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   9.7
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   46 44.8 47.2
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   10
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   42 38.6 45.4
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   7.7+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   65 55 75
Fixing the lever   *
Remarks
Startup boost setting
 
Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   700
Advance angle deg.   1 0.5 1.5
Timer adjustment_04
Pump speed r/min   1100
Advance angle deg.   2.7 2 3.4
Timer adjustment_05
Pump speed r/min   1400
Advance angle deg.   4.4 3.7 5.1
Timer adjustment_06
Pump speed r/min   1500
Advance angle deg.   4.8 4.1 5.5
Timer adjustment_07
Pump speed r/min   -
Advance angle deg.   6 6 6
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101681-9580
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL (5)Rack difference between N = N1 and N = N2
----------
RT=1 TH=2.3mm SXL=10.1+0.2mm DL=5.2-0.2mm N1=1100r/min N2=800r/min
----------

Speed control lever angle

Test data 101681-9580
F:Full speed
----------

----------
a=0deg+-5deg

0000000901

Test data 101681-9580
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=30deg+-3deg

Stop lever angle

Test data 101681-9580
N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

Test data 101681-9580
(1)Pump vertical direction (2)Position of gear's standard installation threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)




Information:

Safety is basically common sense. There are standard safety rules but each situation has its own peculiarities which cannot always be covered by rules. Your experience and common sense will be your best guide to safety. Be ever watchful for safety hazards and correct deficiencies promptly.Use the following safety precautions as a general guide to safe driving and maintenance practice. It is your responsibility to practice and promote safety. 1. Obey the rules of the road.2. Never adjust or repair engine or vehicle while it is in operation.3. Remove all tools and electrical cords before starting engine or operating vehicle.4. Keep work area clean.5. Store oily rags in containers.6. Store flammable liquids in a safe place away from the work area.7. Do not smoke around batteries. Hydrogen gas generated by charging is explosive. Keep batteries in a well ventilated area.8. Observe NO SMOKING signs.9. Do not wear loose clothing.10. Never operate an engine except in a well ventilated area.11. Do not exceed 30 PSI (2 kg/cm2) of air pressure when cleaning with air. Servicing cab-over truck engines require additional safety precautions as follows: Before Tilting Cab:1. Check clearance above and in front of truck cab.2. Keep tool chests and workbenches away from front of cab.3. Inspect sleeper and cab interior for loose luggage, tools and liquid containers which could fall forward.4. Check "Buddy" or "Jump" seats on right side of cab to be sure they are secured in place. While Tilting Cab1. Be sure the governor, transmission and clutch linkage do not interfere with the cab.2. Check position of steering shaft U-joint to prevent binding.
BEFORE TILTING CAB CHECK AREA FOR SUFFICIENT CLEARANCE AND OBSTRUCTIONS3. Never work under a partially tilted cab, unless it is properly secured.4. When cab is tilted past the over-center position, use cables or chains to prevent the cab from falling beyond the over-center point. Do not rely on cab hydraulic lift mechanism to retain or break the fall of the cab. While Cab is Tilted1. If it is necessary to open a door, take care to avoid damage to door hinges and/or window glass. While Lowering Cab1. Watch all governor, steering, clutch and transmission linkage. Bellcranks may turn over center, shift levers jam against bottom of cab and some models of clutch links separate when tilting cab. These clutch linkage components can miss their mating part when the cab is lowered.2. Be sure mating ends of exhaust and air cleaner inlet pipes align properly.3. Be sure cab lowers properly on mounting and locating pins. Twisted or misaligned cabs may miss locating pins and cab latch will not secure cab in locked position.4. Lock cab latching mechanism when cab is all the way down.

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