101608-9410 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016089410

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101608-9410 1016089410

Cross reference number

ZEXEL 101608-9410 1016089410

Zexel num

Bosch num

Firm num

Name

101608-9410

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 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131425-0420

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 92 90.4 93.6

Max. variation between cylinders % 0 -3.5 3.5

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 265 265 265

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 92 91 93

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 96.5 92.5 100.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.25 )

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 90.5 86.5 94.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 105 105 115

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min (900)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1080

Advance angle deg. 2 1.5 2.5

Timer adjustment_03

Pump speed r/min 1225

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 1425

Advance angle deg. 6 5.5 6.5

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=M44
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=39mm
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a=20deg+-5deg b=42deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
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aa=42mm
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a=25deg+-5deg b=40deg+-5deg

0000001501 LEVER

(a) Speed lever (B) Accelerator lever (C) Accelerator lever stopper bolt 1. Accelerator lever setting method With the speed lever in the idling position, back off the accelerator lever stopper bolt L1 from where it contacts point a. (Back off 1+0.5 turns and set.)
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L1=1+0.5mm
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