101601-5300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015300

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5300 1016015300

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Service parts 101601-5300 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-2300

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0220

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 105025-0490

15. NOZZLE SET

Include in #1:

101601-5300 as INJECTION-PUMP ASSEMBLY

106685-4160 as _

Cross reference number

ZEXEL 101601-5300 1016015300

Zexel num

Bosch num

Firm num

Name

101601-5300

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 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 44.6 48.6

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 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(8.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 45.6 47.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 45.2 43.2 47.2

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. 52 50 54

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 36 40

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 *

Injection quantity adjustment_08

Adjusting point E

Rack position R1+0.35

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 28 24 32

Fixing the lever *

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. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C46
----------

Speed control lever angle

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

----------
a=(45deg)+-3deg b=46deg+-5deg

Stop lever angle

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

----------
a=20deg+-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:

Recommended Procedure With Chassis Dynamometer
Possible Causes/Corrections
Minor Operating FaultsTo help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the "Primary Engine Checks" section. Fuel Ratio Control Out Of Adjustment Or DefectiveFollow the procedure in the Testing and Adjusting Section of this Service Manual. Check Engine PerformanceDo a Power Analysis Report (PAR), Level II, to check engine performance. See Special Instruction, Form No. SEHS8025 and SEHS7886 for the tooling and procedures to use. Be sure to make a record of the temperatures for inlet air, fuel (at filter base), lubricating oil and coolant. Make the necessary adjustments or repairs to the engine if needed.At this point, the governor fuel settings should be verified. See the Testing and Adjusting Section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see "Owner/Operator Input" section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.Recommended Procedure Without Chassis Dynamometer
Possible Causes/Corrections
Minor Operating FaultsTo help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the "Primary Engine Checks" section. Fuel Ratio Control Out Of Adjustment Or DefectiveFollow the procedure in the Testing and Adjusting Section of this Service Manual. Fuel Injection Timing Not CorrectFollow the procedures in the Testing and Adjusting Section of this Service Manual. Check Engine PerformanceInstall the tooling and follow the procedure given in the Road Test section.At this point, the governor fuel settings should be verified. See the Testing and Adjusting Section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see "Owner/Operator Input" section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.