101601-9260 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016019260

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-9260 1016019260

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Service parts 101601-9260 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2650

3. GOVERNOR 105490-4770

4. SUPPLY PUMP 105220-5190

5. AUTOM. ADVANCE MECHANIS 105643-0060

6. COUPLING PLATE 105661-0350

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101482-9001 as _

101601-9260 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-9260 1016019260

Zexel num

Bosch num

Firm num

Name

101601-9260

INJECTION-PUMP ASSEMBLY
6110 *

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 132424-0620

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 4.2 4.15 4.25

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 R1(10.7)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 72.5 70.5 74.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.5+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 10.5 9 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 75

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)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL (3)The torque control spring does not operate.
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DL=7.8-0.5mm SXL=R1(10.7)+0.2mm
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Speed control lever angle

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

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

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=5.5deg+-5deg b=(25deg)+-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:

Right Side (6 Cylinder Shown)(1) Depth that cup plugs are installed (measured from block face to top edge of plug) ... 1.25 0.25 mm (.049 .010 in)(2) Distance all sleeves extend from top face ... 14 2 mm (.55 .08 in)(3) Distance two large dowels extend from rear face ... 12.0 0.5 mm (.47 .02 in)(4) Distance two small dowels extend from rear face ... 8.0 0.5 mm (.31 .02 in)(5) Distance all dowels extend from front face ... 8.0 0.5 mm (.31 .02 in)
View A-A (Rear Face)(6) Bores in block for all camshaft bearings except front bearing ... 69.000 0.038 mm (2.7165 .0015 in)(7) Locate bearing oil hole for all camshaft bearings (except front bearing) at top of bore.
Front Face(8) Bore in block for front camshaft bearing ... 70.000 0.025 mm (2.7559 .0010 in)(9) Front camshaft bearing joint location.(10) Front camshaft bearing oil hole. Install front camshaft bearing with bearing oil hole (10) aligned with oil hole in block and bearing joint (9) positioned as shown.(11) Width of main bearing cap ... 159.995 0.020 mm (6.2990 .0008 in) Width of cylinder block for main bearing cap ... 160.000 0.018 mm (6.2992 .0007 in)(12) Bore in block for main bearings ... 95.000 0.013 mm (3.7402 .0005 in)(13) Main bearing cap bolts. Install as follows: Install bearing caps with sequence number to the right, 1 through 5 (for 4 cylinder) or 1 through 7 (for 6 cylinder), front to rear.a. Before assembly, put 2P2506 Thread Lubricant on the bolt threads and washer face.b. Tighten both bolts of each bearing cap to a torque of ... 54 7 N m (40 5 lb ft)c. Then tighten bolts an additional ... 90 5 degrees (1/4 turn)(14) Location of bearing cap sequence number.(15) Dimension from centerline of crankshaft bore to pan rail ... 110.00 mm (4.331 in)(16) Dimension from centerline of crankshaft bore to top of block ... 322.00 .017 mm (12.677 .0007 in)(17) Cylinder bore size ... 105.025 .025 mm (4.1348 .0010 in) Bore size must be checked with a 4C4377 Cylinder Head Stress Plate and gasket installed. Refer to Installation Of 7C6208 Cylinder Sleeve, Special Instruction Form No. SEHS9047. (18) Piston cooling jet. Check piston cooling jets by inserting a 1.3 mm (.05 in) diameter drill rod into jet. Rod must pass through a 5.0 mm (.20 in) diameter circle in location (A) and a 13 mm (.51 in) diameter circle in location (B). Dimension (C) is 25.9 mm (1.02 in). Dimension (D) is 33.4 mm (1.31 in). Dimension (E) is 26.95 mm (1.061 in). Dimension (F) is 9.8 mm (.39 in). Dimension (G) is 50 mm (2.0 in). Distance four sleeves (19) extend from side face ... 5.0 0.5 mm (.20 .02 in)