101606-6570 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066570

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101606-6570 1016066570

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Service parts 101606-6570 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9690

3. GOVERNOR 105931-6260

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0540

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101402-4910 as _

101606-6570 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101606-6570 1016066570

Zexel num

Bosch num

Firm num

Name

101606-6570

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 131424-5520

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)
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
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 -

Rack position 11.1

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 63.7 61.8 65.6

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.6+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 10.2 8.7 11.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 63.7 62.7 64.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 81.3 77.3 85.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 41.7 37.7 45.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 63 83

Fixing the lever *

Rack limit *

Injection quantity adjustment_07

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 10 8.5 11.5

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2.7 2.2 3.2

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=D95
----------

Speed control lever angle

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

----------
a=18.5deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed = cc. (3)Rack position = approximately dd (4)Free (at shipping)
----------
aa=1400r/min bb=6.7-0.5mm cc=275r/min dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(0deg)

Information:

(1) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in)(2) Bore diameter in cylinder block for the cylinder liners ... 136.00 0.03 mm (5.354 .001 in)(3) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in) (4) Spacer block.(5) Height of dowels above top surface of spacer block and cylinder block ... 8.00 0.03 mm (.315 .001 in)(6) Cylinder Liner. Make reference to the procedure for checking Cylinder Liner Projection in Testing And Adjusting Section of Service Manual Form No. SENR3909.Cylinder liner projection above the top surface of the spacer block must be ... 0.12 0.08 mm (.005 .003 in) Apply 7M7260 Liquid Gasket as required to cylinder liner shoulder and cylinder block face joint of all liners. (7) Depth plug is to be installed (from end surface of cylinder block to top of plug) ... 1.25 0.25 mm (.049 .010 in)(8) Diameter of camshaft bores ... 75.000 0.025 mm (2.9530 .0010 in)(9) Oil cooling jet assembly. Tighten bolt that holds oil cooling jet to ... 25 7 N m (18 5 lb ft)(10) Width of main bearing cap ... 175.00 0.02 mm (6.8898 .0008 in)Width in cylinder block for main bearing cap ... 175.000 0.018 mm (6.8898 .0007 in)(11) Distance from centerline of crankshaft bore to top surface of cylinder block ... 265.0 mm (10.43 in)The flatness across the top contact surface of the block must be within 0.05 mm (.002 in) for any 150 mm (5.9 in) section of the surface.(12) Distance from centerline of crankshaft to bottom surface of cylinder block ... 120.0 mm (4.72 in)(13) Main bearing cap bolts. Install as follows:Main bearing caps shall be assembled with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.Main bearing cap bolts to be lubricated on threads and washer face with SAE 30 oil or molylube. Tighten bolts to 95 5 N m (70 4 lb ft) plus 90 5° additional turnprior to machining. Tighten bolts simultaneously or tighten both bolts to 95 N m (70 lb ft) before turning the additional 90°.(14) Bore in cylinder block for seven main bearings ... 108.000 0.013 mm (4.2520 .0005 in) All main bearing bore measurements are to be made before caps are disassembled.