101601-5500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015500

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-5500 1016015500

Cross reference number

ZEXEL 101601-5500 1016015500

Zexel num

Bosch num

Firm num

Name

101601-5500

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 131424-5720

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 9.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.9 59.9 63.9

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 8.4+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 9 7.5 10.5

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.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.3)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.9 60.9 62.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position R1+0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 66.3 64.3 68.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 40.5 38.5 42.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point E

Rack position R1-0.1

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 29.7 27.7 31.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 99 99 109

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500-50

Advance angle deg. 3.5 3 4

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=D84
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Speed control lever angle

F:Full speed I:Idle (1)- (2)Stopper bolt setting
----------

----------
a=(31deg)+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)