101609-3610 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093610

Information Cross number Calibration Data Calibration Data Ex

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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

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
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K=10 P1=(127+-10kPa{1.3+-0.1kgf/cm2}) BCL=0.55+-0.1mm N1=1100r/min N2=400r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(11deg)+-5deg b=(33deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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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.
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h=2.7mm c=6deg+-30min
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Timing setting

(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
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aa=12deg bb=0deg cc=2.7+-0.01mm
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a=55deg48min+-3deg b=55deg48min+-3deg13min48sec c=6deg+-30min