101601-9461 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016019461

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-9461 1016019461

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Service parts 101601-9461 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-1810

3. GOVERNOR 105482-0240

4. SUPPLY PUMP 105210-4710

5. AUTOM. ADVANCE MECHANIS 105644-0190

6. COUPLING PLATE 105661-0391

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:

101601-9461 as INJECTION-PUMP ASSEMBLY

104303-2210 as _

Cross reference number

ZEXEL 101601-9461 1016019461

Zexel num

Bosch num

Firm num

Name

101601-9461

INJECTION-PUMP ASSEMBLY
SX6130 *

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 1.95 1.9 2

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 10.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 126 124 128

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 15 13.5 16.5

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. 140 140

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 450--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 400

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 2.2 1.7 2.7

Timer adjustment_04

Pump speed r/min 1000

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting (3)Set the main spring and the damper spring. (4)Rack difference between N = N1 and N = N2
----------
SXL=11.1+0.2mm N1=1000r/min N2=600r/min
----------

Speed control lever angle

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

----------
a=5deg+-5deg b=19deg+-5deg

0000000901

F:Full load
----------

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

Stop lever angle

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

----------
a=36deg+-5deg b=71deg+-5deg

Timing setting

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

----------
a=(40deg)

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. Refer to LEBV2810 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. Fuel Settings Not CorrectIf the Power Analysis Report indicates a problem, 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. Defective Fuel Nozzle(s)Remove the fuel nozzles and test as in the Testing and Adjusting Section of this Service Manual.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 DefectiveCheck engine timing with the 8T5300 Timing Indicator Group. Follow 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. Fuel Settings Not CorrectIf the Road Test indicates a problem, 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. Any Further Diagnosis Must Be Done On A Chassis DynamometerIf the fuel settings are correct and the above procedures have been followed without finding the problem a Power Analysis Report (PAR), Level II, must be done on the engine. Refer to LEBV2810 and SEHS7886 for the correct tools and procedures to use.