101601-9862 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016019862


101601-9862 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101601-9862 1016019862

Cross reference number

ZEXEL 101601-9862 1016019862


Zexel num
Bosch num
Firm num
Name
101601-9862 
 
   
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   131424-5520
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   3.3 3.25 3.35
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   10.75+-0 .5
Pump speed r/min   800 800 800
Each cylinder's injection qty mm3/st.   46.7 45.5 47.9
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   8.7+-0.5
Pump speed r/min   500 500 500
Each cylinder's injection qty mm3/st.   7.6 6.5 8.7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.75 )
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   46.7 45.7 47.7
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   (R1+0.4)
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   66.1 64.1 68.1
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.1
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   45.5 41.5 49.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.3+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   73 63 83
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_07
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   8.7 7.4 10
Fixing the rack   *
Remarks
(check)
 
Timer adjustment
Pump speed r/min   1250--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.8
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-9862
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=F53
----------

Speed control lever angle

Test data 101601-9862
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101601-9862
N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Rack position = approximately aa. (3)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection. (4)After setting the stopper bolt, confirm non-injection at speed = dd. Rack position = ee (non-injection rack position)
----------
aa=17.4mm bb=1550r/min cc=6.7-0.5mm dd=275r/min ee=(8.3)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

Test data 101601-9862
(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=16deg
----------
a=(1deg)




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