101601-5140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5140 1016015140

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Buy INJECTION-PUMP ASSEMBLY 101601-5140 zexel genuine, new aftermarket engine parts with delivery

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

106682-4920 as _

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

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

Speed control lever angle

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

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

Stop lever angle

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

(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

(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:
Do not let the tops of the nozzles turn while the fuel lines are loosened. The nozzles will be damaged if the top of the nozzle turns in the body. Defective fuel nozzles will damage the engine due to improper spray patterns.
a. remove fuel injection lines
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove clamp (1). 2. Install tool (A). Turn screw (2) out until the button on the screw almost makes contact with the inside of the nozzle puller. Tilt the tool approximately 45° and place it over the nozzle.3. Tilt the nozzle puller (A) up so the inside lip of the puller is under the stepped diameter of the nozzle.4. Turn screw (2) down until the button goes into the bolt hole for the nozzle hold down clamp.
Do not exceed a torque of 17 N m (13 lb ft) on the screw in tooling (A) to remove the nozzle. Added force can cause the stem of the nozzle to bend or break off.
5. Turn screw (2) to lift the nozzle out of its bore. If necessary, after the nozzle is loose in its bore, move it up and down to help loosen any carbon and make removal easier. 6. If the nozzle can not be removed with tooling (A), tooling (B) must be used. When tooling (B) is used, the nozzle normally can not be used again, and a new nozzle will need to be installed as a replacement.
Hold tool (B) so the center line of tool (B) is the same as the extended center line of fuel injection nozzle (2). This will prevent distortion of the fuel injection nozzle which can cause the nozzle to bend or break off.
7. Remove the protective cap and install tooling (B).8. Use the slide hammer to remove fuel injection nozzle (3).9. Remove the compression seal.10. For nozzles removed using tool (A), remove the carbon dam seal on the end of the nozzle. The following steps are for the installation of the fuel injection nozzles. Tool (C) must be modified by drilling it out to a diameter of 8.5 mm (.344 in) and to a depth of 1.5 mm (.060 in) before it can be used on the 8N7002 Fuel Injection Nozzle.11. Use tool (C) to install carbon dam seal (4).12. To clean the nozzles, see Special Instruction SEHS7292 for the use of tooling (D).13. Install new compression seal (5). 14. Use tool (E) to clean the bore for the fuel injection nozzle. 15. Install fuel injection nozzle (6).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzle turns in the body.
End By:a. install fuel injection lines