101602-1560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016021560

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-1560 1016021560

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Buy INJECTION-PUMP ASSEMBLY 101602-1560 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-1560 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8040

3. GOVERNOR 105411-1780

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-7220

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4850

11. Nozzle and Holder ME078538

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3350

14. NOZZLE 105025-1870

15. NOZZLE SET

Include in #1:

101602-1560 as INJECTION-PUMP ASSEMBLY

103672-0393 as _

Cross reference number

ZEXEL 101602-1560 1016021560

Zexel num

Bosch num

Firm num

Name

101602-1560

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SEJ967d}

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 131424-5620

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 4.5 4.45 4.55

Beginning of injection position
Governor 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 9.6

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 122 118.5 125.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.5 9 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-0.75

Boost pressure kPa 28 25.3 30.7

Boost pressure mmHg 210 190 230

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(9.6)

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Rack difference between N = N1 and N = N2 (5)Set idle sub-spring
----------
K=16 BCL=0.75+-0.1mm N1=750r/min N2=250r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Pump speed = aa (3)Pump speed = bb
----------
aa=750r/min bb=900r/min
----------
a=1deg+-5deg b=22deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of coupling's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(1deg)

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Premature wear of 162-2220 Check Valve in the 217-7455 Fuel Filter Base can cause low fuel pressure or injector malfunction.Solution
There are two solutions that can deal with the problem stated above and are listed below :
Replace the 162-2220 Check Valve with a new part.
Install an external check valve on the high-pressure outlet of the 217-7455 Fuel Filter Base .The procedure that follows below covers the process of installing an external check valve on the outlet of the pump. Table 1 lists the parts needed to install the external check valve.
Table 1
Item Qty New Part Number Part Description
1 1 238-5080 O-Ring Seal
2 1 238-5081 O-Ring Seal
3 1 305-6991 Elbow
4 1 420-1796 Check Valve
Illustration 1 g03420967
Install elbow (3) with o-ring seal (2) into the outlet of the fuel filter base.
Install check valve (4) with o-ring seal (1) into elbow (3) .
Illustration 2 g03421982
Install the fuel hose back onto check valve (4). Check for any leaks after installation.