101607-6071 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076071

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6071 1016076071

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Service parts 101607-6071 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105931-9321

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5140

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7061

11. Nozzle and Holder ME076952

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3030

14. NOZZLE

15. NOZZLE SET 105019-0230

Include in #1:

101402-7490 as _

101607-6071 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101607-6071 1016076071

Zexel num

Bosch num

Firm num

Name

101607-6071

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 131424-8420

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 3.2 3.15 3.25

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 11.7

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 77.4 75.1 79.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.4 76.4 78.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 87.7 83.7 91.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 56 52 60

Fixing the lever *

Injection quantity adjustment_06

Adjusting point E

Rack position (R1+0.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 87.6 83.6 91.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1080

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1390

Advance angle deg. 6 5.5 6.5

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=H50
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(42deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(42deg)+-3deg c=18.5deg+-5deg

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=10deg
----------
a=(2deg)

Information:

Illustration 1 g00563639
Schematic of the RTD module
Illustration 2 g00563641
Schematic of the RTD
Illustration 3 g00562911
Schematic of the RTDFunctional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Check the RTD.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the RTD from the wiring harness. This is done by removing the RTD connector head.
Measure the resistance on the sensor. Measure the resistance between the following terminals: Terminal 1 and Terminal 2.
Use table 1 in order to determine if the RTD is functioning normally.
Table 1
RTD
Temperature and Resistance
Temperature Ohms Difference per °C
0 °C (32 °F) 100.00 0.39
10 °C (50.0 °F) 103.90 0.39
20 °C (68 °F) 107.79 0.39
30 °C (86 °F) 111.67 0.39
40 °C (104 °F) 115.54 0.39
50 °C (122 °F) 119.40 0.39
60 °C (140 °F) 123.24 0.38
70 °C (158 °F) 127.07 0.38
80 °C (176 °F) 130.89 0.38
90 °C (194 °F) 134.70 0.38
100 °C (212 °F) 138.50 0.38
110 °C (230 °F) 142.29 0.38
120 °C (248 °F) 146.06 0.38
130 °C (266 °F) 149.82 0.37
140 °C (284 °F) 153.58 0.37
150 °C (302 °F) 157.31 0.37 The results of the preceding procedure are in the following list:
The resistance is correct. The RTD is functioning normally. Proceed to 3.
The resistance is not correct. The RTD is not functioning normally. Replace the RTD. Stop.
Measure the resistance of the interconnect wiring harness.
Connect the RTD to the wiring harness. This is done by connecting the RTD connector head.
Locate the RTD terminal and locate the sense terminal. The terminals are located in the MECP. The RTD terminal is terminal 2 and the sense terminal is terminal 3.Reference: Schematic, RENR2458, "3600 Diesel Marine Monitoring System Electrical System".
Measure the resistance on the