101609-3610 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093610


101609-3610 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101609-3610 1016093610

Cross reference number

ZEXEL 101609-3610 1016093610


Zexel num
Bosch num
Firm num
Name
101609-3610 
 
   
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   131424-3420
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   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   1-5-3-6- 2-4
Pre-stroke mm   2.7 2.65 2.75
Rack position
After adjusting injection quantity.
  R=A
Beginning of injection position
Drive 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   9.1
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   99.5 98.5 100.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   40 40
Boost pressure mmHg   300 300
Hydraulic cylinder ON   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.4+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   9.5 8.5 10.5
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Hydraulic cylinder ON   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   D
Rack position   9.3++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 75 85
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Hydraulic cylinder OFF   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   850 850 850
Rack position   R1-0.55
Boost pressure kPa   10 8.7 11.3
Boost pressure mmHg   75 65 85
Boost compensator adjustment_02
Pump speed r/min   850 850 850
Rack position   R1(9.1)
Boost pressure kPa   26.7 26.7 26.7
Boost pressure mmHg   200 200 200

Test data Ex:

Governor adjustment

Test data 101609-3610
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (When hydraulic cylinder is OFF) (4)When hydraulic cylinder ON: P1 (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
----------
K=10 P1=(127+-10kPa{1.3+-0.1kgf/cm2}) BCL=0.55+-0.1mm N1=1100r/min N2=400r/min
----------

Speed control lever angle

Test data 101609-3610
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(11deg)+-5deg b=(33deg)+-5deg

Stop lever angle

Test data 101609-3610
N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Adjusting procedure for load plunger equipped pump with RSV (cam lock) governor (see service information S.I. 434 for details). At cam lift h+-0.01, set the camshaft c deg from the * mark in accordance with the timing adjustment procedure. 2. Align the flyweight's timing tooth position and the lock pin groove and then fully tighten the flyweight to the camshaft. Then, remove the lock pin. 3. Adjust the maximum variation between cylinders and injection quantity. 4. Adjust using the pre-stroke adjusting shim so that the pre-stroke value is the value for 4/4 load (standard point A). 5. After adjusting the pre-stroke, reconfirm that the injection quantity and the maximum variation between cylinders are as specified. 6. At delivery, again fix the flyweight using the lock pin.
----------
h=2.7mm c=6deg+-30min
----------

Timing setting

Test data 101609-3610
(1)Pump vertical direction (2)Key groove position for No. 1 cylinder's cam lift h = cc (at BTDC aa). (3)Key groove position for No. 1 cylinder's beginning of injection (at point A after injection quantity adjustment). (4)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (5)B.T.D.C.: aa
----------
aa=12deg bb=0deg cc=2.7+-0.01mm
----------
a=55deg48min+-3deg b=55deg48min+-3deg13min48sec c=6deg+-30min




Have questions with 101609-3610?





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