101608-6150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086150

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101608-6150 1016086150

Cross reference number

ZEXEL 101608-6150 1016086150

Zexel num

Bosch num

Firm num

Name

101608-6150

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 4.5 4.45 4.55

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 A

Rack position 11.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 142.5 141.5 143.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 73.3 73.3

Boost pressure mmHg 550 550

Injection quantity adjustment_02

Adjusting point C

Rack position 7.6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10

Boost pressure kPa 21.3 18.6 24

Boost pressure mmHg 160 140 180

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 11.2

Boost pressure kPa 60 53.3 66.7

Boost pressure mmHg 450 400 500

Timer adjustment

Pump speed r/min 1100++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1100.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 4 4 4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke: BCL
----------
K=8 BCL=1.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(20deg)+-5deg b=(3deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(7deg)