101600-3050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016003050

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101600-3050 1016003050

Cross reference number

ZEXEL 101600-3050 1016003050

Zexel num

Bosch num

Firm num

Name

101600-3050

INJECTION-PUMP ASSEMBLY
14BF PE6AD PE

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 134424-4120

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.6 3.55 3.65

Rack position
Point A R=A

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 10.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 160.5 159.5 161.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 133 133

Boost pressure mmHg 1000 1000

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.5+-0.5

Pump speed r/min 460 460 460

Average injection quantity mm3/st. 14.5 12.5 16.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-1.6

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(10.6)

Boost pressure kPa 120 113.3 126.7

Boost pressure mmHg 900 850 950

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)When the hydraulic cylinder is OFF (6)When hydraulic cylinder ON: P1 (7)Boost compensator stroke: BCL (8)Main spring setting (9)Set idle sub-spring
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K=13 P1=(127+-10kPa{1.3+-0.1kgf/cm2}) BCL=1.6+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=0deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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a=25deg+-5deg b=53deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
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T1=7.16~9.12N-m(0.73~0.93kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m) T3=2.9~4.4N-m(0.3~0.45kgf-m)
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Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
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aa=7deg bb=0deg
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a=54deg42min+-3deg b=3deg30min+-30min