101601-9231 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016019231

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-9231 1016019231

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Service parts 101601-9231 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3280

3. GOVERNOR 105490-5150

4. SUPPLY PUMP 105220-5200

5. AUTOM. ADVANCE MECHANIS 105643-0240

6. COUPLING PLATE 105661-0350

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5560

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3522

14. NOZZLE 105015-5150

15. NOZZLE SET

Include in #1:

101601-9231 as INJECTION-PUMP ASSEMBLY

104303-3380 as _

Cross reference number

ZEXEL 101601-9231 1016019231

Zexel num

Bosch num

Firm num

Name

101601-9231

INJECTION-PUMP ASSEMBLY
6110A *

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)
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 3.3 3.25 3.35

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 10.7

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 57.2 55.2 59.2

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 9.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8.8 7.3 10.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 73

Fixing the lever *

Remarks
After 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 1000

Advance angle deg. 3.2 2.7 3.7

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Beginning of damper spring operation: DL (5)Rack difference between N = N1 and N = N2
----------
RT=1 TH=2.7mm SXL=11+0.2mm DL=6.5-0.5mm N1=1500r/min N2=800r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=20deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=55mm
----------
a=5.5deg+-5deg b=24deg+-3deg

Stop lever angle

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

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

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

Start By:a. remove cylinder head assemblyb. remove front housing groupc. remove flywheel housingd. remove crankshaft rear seal assemblye. remove piston and connecting rod assemblies 1. Remove bolts (1). Remove main bearing caps (2). Remove thrust bearings (3) from the center main. Main bearing caps are identified by numbers one through seven. Unmarked caps should be marked by stamping the appropriate number toward the right side on the bottom prior to the removal. 2. Install a suitable size bolt in each end of the crankshaft as shown. Fasten two lifting straps (4) to the bolts in the crankshaft and to a hoist as shown. Carefully, remove the crankshaft. The appropriate weight of the crankshaft is 129 kg (285 lb).3. Remove the upper portions of the main bearings. The following steps are for the installation of the crankshaft.
Be sure the main bearing tabs engage with the grooves in the block and cap.
4. Position the upper portion of the main bearings in the cylinder block. Lower the main bearing portion in caps (2). Be sure everything is clean and only the bearing face is lubricated with clean engine oil.5. Fasten a hoist to the crankshaft, and position it in the cylinder block. 6. Install thrust bearings (3).7. Install main bearing caps (2) with the part numbers toward the right hand side of the cylinder block. Take care to ensure the caps are numbered one through seven from the front of the engine. Put clean engine oil or molylube on the bolt threads and the washer face; then install bolts (1). Tighten the bolts on the side where the main bearing tabs are located to a torque of 95 5 N m (70 4 lb ft). Tighten the bolts on the opposite side to a torque of 95 5 N m (70 4 lb ft).8. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn.
Typical Example9. Use tooling (A) to measure crankshaft end play. The crankshaft end play must be 0.10 to 0.50 mm (.004 to .020 in).End By:a. install piston and connecting rod assembliesb. install crankshaft rear seal assemblyc. install flywheel housingd. install front housing groupe. install cylinder head assembly