101607-6597 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076597

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6597 1016076597

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Service parts 101607-6597 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8850

3. GOVERNOR 105931-9995

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105672-5230

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7183

11. Nozzle and Holder ME075761

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

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET

105019-0371

Include in #1:

101607-6597 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-5540 as _

Cross reference number

ZEXEL 101607-6597 1016076597

Zexel num

Bosch num

Firm num

Name

101607-6597

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 11.8

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 80 77.6 82.4

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 600 600 600

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(11.8)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 80 79 81

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 85 81 89

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 55 51 59

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 85 105

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 1 0.5 1.5

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 7 6.5 7.5

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=L01
----------

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 (speed lever full, speed = ff). (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
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=7deg
----------
a=(4deg)

Information:

Illustration 3 g01077676
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) Seal (12) Check valve assemblies (Qty 7)Removing the Check Valve Assemblies from the HEUI Pump
Remove the two high pressure seals (10). Discard the two seals. Refer to Illustration 3.Note: Take caution in order to avoid wiping any debris into the pump.
Remove the seal (11) from the bearing on the fuel transfer pump. Discard the seal. Refer to Illustration 3.
Remove the seven check valve assemblies (12) from the HEUI pump by using Tooling (A). Refer to Illustration 3.Note: Take caution in order to avoid wiping any debris into the pump.
Inspect all check valve assemblies (12) for broken springs by using the following procedure.
Place the flat end of the check valve on a work bench so that the valve is positioned vertically.
Press on the check valve poppet (13) with a small cross tip screwdriver and then release the check valve poppet. There should be some resistance from the spring in the check valve. The poppet should return to the initial position after releasing. Refer to Illustration 4.
Illustration 4 g01077708
(12) Check valve assembly (13) Check valve poppet
If any of the valve springs are broken, do not advance. Stop the rework procedure. Replace the HEUI pump.
If none of the valve springs are broken, proceed to the next section.Installing Check Valve Assemblies into the HEUI Pump
Install seven new 254-4302 Check Valve Assemblies (12) that are found in the 254-4334 Check Valve Kit .
Insert the check valve assemblies by hand and press on the back of the valve until the valve is fully seated in the barrel.
Tighten each valve to 9.0 1.5 N m (80 13 lb in) by using an appropriate torque wrench and Tooling (A) .Note: The check valve assemblies must be torqued to the correct specifications. Failing to apply the correct torque could result in loosening of the valve or cracking of the valve in the field.
In order to ensure that all valves are torqued, repeat Step 3.Installing the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 5.
Illustration 5 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 6. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 6 g01077908
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Failure to align the drive tang prior to the installation of the fuel transfer pump will not allow proper assembly of the two pumps.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten the bolts to a torque of 4.0 0.2 N m (35 1.5