101601-5031 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5031 1016015031

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101601-5031 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5031 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-0460

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0240

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-5640

15. NOZZLE SET

Include in #1:

101601-5031 as INJECTION-PUMP ASSEMBLY

106682-9030 as _

106682-9031

Cross reference number

ZEXEL 101601-5031 1016015031

Zexel num

Bosch num

Firm num

Name

101601-5031

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 8.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.2 47.2 51.2

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+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8 6.5 9.5

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(8.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.2 48.2 50.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 45 43 47

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 55.7 53.7 57.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.15

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 38.7 36.7 40.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 13.5+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 95 105

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 5 4.7 5.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=90
----------

Speed control lever angle

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

----------
a=33deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-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)

Information:

Start By:a. remove shutoff solenoidb. remove governorc. remove governor spring groupd. remove rear cover group 1. Remove riser (1). 2. Remove retaining ring (2), races (3) with bearing (4) and shims (5). 3. Remove four flyweight bolts (6) with washers.4. Remove flyweights (7), toe (8) and pins (9). Keep parts of each flyweight group together.5. Remove pin (9). Inspect for wear.6. Remove flyweight toe (8). Inspect for wear.7. Inspect flyweight pin bore for wear. Replace any flyweight parts with wear.8. Hold flyweight carrier (10) to keep from rotating, and remove eight carrier bolts (11). Replace, do not reuse, eight carrier bolts (11),9. Remove flyweight carrier (10), riser shaft (12) and the drive pin.10. Remove fuel transfer pump (13) and the fittings. See the topic, Remove Fuel Transfer Pump.11. Remove two bolts (14) and remove shutoff assembly (15). 12. If necessary, remove levers (16), (17) and remove spring (18). These components are part of the shutoff assembly service replacement. Do not disassemble shutoff assembly beyond this point. 13. Remove throttle spring (23), setscrew (19), spring (20) and lever (21).14. Remove retaining ring (22) and pull throttle shaft assembly (24) out of the housing bore. Do not disassemble throttle shaft assembly beyond this point.15. If necessary, remove the throttle shaft seal.16. Remove governor front housing from Repair Stand, and turn it over. If not previously removed, remove the housing o-ring seal. 17. Remove drive gear bolt (25) and lift cover (26) from the gear drive unit.
Be careful not to damage the "C" spring, by over compressing with the vise.
18. Use a vise to remove "C" (27). Remove gear assembly (28). Do not disassemble the gear beyond this point
Do not attempt to remove the gear carrier, it is serviced as part of the housing assembly.
The following steps are for the assembly of the front housing.19. Position gear (28) onto carrier (29). Assemble with short length, 8.43 mm (.332 in.), of dowel pin in gear assembly, face down (toward housing). Be sure gear rotates freely on carrier bore.
Be careful not to damage the "C" spring, by over compressing with the vise.
20. Install "C" spring (27). Be sure that there is preload when assembled. Orient cover so the dowel, which is pressed into carrier (29), fits into the hole in the cover. The dowel from the gear assembly fits into the slot in the cover.21. Install cover (26) and bolt (25).22. Mount front housing to repair stand.23. If the throttle shaft seal was removed, install it with the lip toward the inside of the governor.24. Install throttle shaft (24) into housing bore, and install retaining ring (22).25. Slide lever (21) and spring (20) onto throttle shaft. The long leg of spring (20) fits into slot on lever (21). The other end of spring (20) fits into slot on the throttle shaft.26. Install throttle spring (23). These parts must be oriented correctly for proper governor operation. Following is a quick check for proper assembly.27. With zero preload on spring, the threaded hole in throttle