Rating:
Information injection-pump assembly
ZEXEL
101603-1420
1016031420
Cross reference number
ZEXEL
101603-1420
1016031420
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
131424-4620
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.5
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
88
85.8
90.2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.2+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
10.5
9
12
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
88
87
89
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_04
Adjusting point
D
Rack position
11.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
67
65
69
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
11.5
Boost pressure
kPa
33.3
32
34.6
Boost pressure
mmHg
250
240
260
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
12.5
Boost pressure
kPa
46.7
40
53.4
Boost pressure
mmHg
350
300
400
Timer adjustment
Pump speed
r/min
1150+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
2
1.5
2.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Boost compensator stroke
----------
DL=6-0.2mm
----------
----------
DL=6-0.2mm
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=35deg+-3deg b=43deg+-5deg
----------
----------
a=35deg+-3deg b=43deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=0deg+-5deg b=41.5deg+-5deg
----------
----------
a=0deg+-5deg b=41.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '2' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(90deg)
----------
aa=16deg
----------
a=(90deg)