101608-1190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081190

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101608-1190 1016081190

Cross reference number

ZEXEL 101608-1190 1016081190

Zexel num

Bosch num

Firm num

Name

101608-1190

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 131424-8420

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 3.2 3.15 3.25

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 11.8

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 80 77.6 82.4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 600 600 600

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.8)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 80 79 81

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 85 81 89

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 55 51 59

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 85 105

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 1 0.5 1.5

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 1400 1400 1400

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
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T1=L01
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=18.5deg+-5deg b=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee (speed lever full, speed = ff). (4)Free (at delivery)
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aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
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a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
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b=42deg+-3deg c=18.5deg+-5deg

0000001601 LEVER

(A) Accelerator lever stopper bolt (B) Link (c) Nut (D) Lever (E) Pin (f) lever (G) Stopper bolt (H) Return spring (J) Pin (E) contacts lever. (K) Load sensor terminal (1)Black (2)Blue-yellow (3)Blue-red Setting the accelerator lever angle, load sensor adjustment 1. Accelerator lever setting method (1)Position the speed lever against the idle stopper bolt and fix. (2)Screw in the accelerator lever stopper bolt (A) and back off the stopper bolt (A) from the position where the accelerator lever pin contacts the speed lever and set. (Gap: approx. 1 mm) Tightening torque: 4.9~7 N.m {0.5~0.7 kgf.m} 2. Load sensor adjustment (See fig 1) (1)Load sensor output measuring circuit Apply DC5+-0.01V to the load sensor terminals and measure the output voltage. (2)Load sensor output adjustment procedure Hold the speed lever against the full side stopper bolt and fix. Adjust the load sensor output voltage to VF = 0.417+-0.1 V using the link (B) and then fix temporarily using nut (C). Turn the speed lever from the idle side to the full side and confirm that output voltage VF = 0.417+-0.1 V is obtained. Confirm several times and then fix using nut (C). Tightening torque: 3.4~4.9 N.m {0.35~0.5 kgf.m} 3. Setting the step motor's idle side stopper bolt After adjustment in previous 1 and 2, position speed lever against idle stopper bolt and fix. Then, screw in stopper bolt G until step motor lever D's pin E contacts lever F. Back off 10+2 deg (approx. 3.5 mm) from this position and fix G. (See fig. 3) 4. Speed lever return confirmation (1)Remove return spring (H) and confirm that the speed lever is returned to the idle position by the torsion spring. (2)Reinstall the return spring (H) in its original position.
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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)-
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aa=7deg
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a=(4deg)