Rating:
Information injection-pump assembly
ZEXEL
101602-9410
1016029410
Cross reference number
ZEXEL
101602-9410
1016029410
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
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
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.2
72.2
74.2
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Boost pressure
kPa
14.7
14.7
Boost pressure
mmHg
110
110
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
55
54
56
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
14.7
14.7
Boost pressure
mmHg
110
110
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.7
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
42.6
40.6
44.6
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
D
Rack position
7.8+-0.5
Pump speed
r/min
290
290
290
Average injection quantity
mm3/st.
9.5
7.7
11.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
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_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
57
57
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
8.7
Boost pressure
kPa
4
4
4
Boost pressure
mmHg
30
30
30
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
9.3
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Boost compensator stroke
(3)Variable speed specification: idling adjustment
(4)Main spring setting
----------
DL=6.5-0.2mm
----------
----------
DL=6.5-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=22deg+-5deg b=(18deg)
----------
----------
a=22deg+-5deg b=(18deg)
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=19deg+-5deg b=22deg+-3deg
----------
----------
a=19deg+-5deg b=22deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=71deg+-5deg
----------
----------
a=45deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)