Rating:
Information injection-pump assembly
ZEXEL
101603-1990
1016031990
Cross reference number
ZEXEL
101603-1990
1016031990
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
131424-5520
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
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
12.1
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
88
85.4
90.6
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-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(12.1)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
88
87
89
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.2
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
92
90
94
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.7
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
68.5
66.5
70.5
Fixing the lever
*
Boost pressure
kPa
28.7
28.7
28.7
Boost pressure
mmHg
215
215
215
Injection quantity adjustment_06
Adjusting point
I
Rack position
13.9+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-1.1
Boost pressure
kPa
19.3
19.3
19.3
Boost pressure
mmHg
145
145
145
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1-0.7
Boost pressure
kPa
28.7
27.4
30
Boost pressure
mmHg
215
205
225
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(12.1)
Boost pressure
kPa
45.3
38.6
52
Boost pressure
mmHg
340
290
390
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=A08 BCL=1.1+-0.1mm
----------
----------
T1=A08 BCL=1.1+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C3=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C3=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=41deg+-3deg
----------
----------
a=18.5deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the stopper bolt at speed = rated point and rack position = aa and confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed = bb. Rack position = cc.
(3)Rack position = approximately dd
(4)Free (at shipping)
----------
aa=6mm bb=275r/min cc=(8.5)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
----------
aa=6mm bb=275r/min cc=(8.5)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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=400+-5r/min Ra=9.2mm
----------
----------
N1=400+-5r/min Ra=9.2mm
----------
0000001601 RACK SENSOR
R:Rack position (mm)
V:Voltage (V)
After installing the rack sensor, confirm the output value (VR).
----------
N1=- Ra=R1(12.1)mm VR=1.94+-0.01V
----------
----------
N1=- Ra=R1(12.1)mm VR=1.94+-0.01V
----------
Timing setting
(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=15deg
----------
a=(0deg)
----------
aa=15deg
----------
a=(0deg)