Rating:
Information injection-pump assembly
ZEXEL
101601-5161
1016015161
Cross reference number
ZEXEL
101601-5161
1016015161
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.1
3.07
3.13
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
8.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68
67
69
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.9+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(8.9)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68
67
69
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
105
105
115
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
4
3.5
4.5
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
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T1=B94
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T1=B94
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Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
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----------
a=23deg+-5deg b=(46deg)+-3deg
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a=23deg+-5deg b=(46deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the normal set bolt.
(2)Engine normal
(3)Engine stop
----------
----------
a=(0deg)+-5deg b=(13deg) c=11deg+-5deg d=40deg+-5deg
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a=(0deg)+-5deg b=(13deg) c=11deg+-5deg d=40deg+-5deg
0000001501 LEVER
(A) Pump's normal lever
(B) Engine's normal lever
(C) Engine stop
(D) Pump stop
(E) Stop direction (perpendicular)
(F) Normal set bolt
(g) rack limit
Stop lever angle and engine's normal setting procedures
(1)After completing adjustment, confirm that the pump's normal lever angle and the pump's stop lever angle are within the specifications in the figure above.
(2)Before setting the rack limit, screw in the normal set bolt, return it 1 turn from point I and then fix the normal set bolt using the locknut. (engine normal)
(3)With the lever at idle and N = Na, pull the stop lever in the stop direction so that the rack position is the non-injection position. Measure the angle at this time. (Engine stop)
(4)Set the rack limit. (Point I adjustment)
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Na=275r/min ra=37mm a=(0deg)+-5deg b=(13deg) c=11deg+-5deg d=40deg+-5deg
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Na=275r/min ra=37mm a=(0deg)+-5deg b=(13deg) c=11deg+-5deg d=40deg+-5deg
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Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
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a=(60deg)
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a=(60deg)