101441-9690 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101441-9690 1014419690

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Service parts 101441-9690 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8300

3. GOVERNOR 105410-9960

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS 105622-1670

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105148-1120

11. Nozzle and Holder 16600-43G02

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105078-0050

14. NOZZLE

105007-1130

15. NOZZLE SET

Include in #1:

101441-9690 as INJECTION-PUMP ASSEMBLY

103662-2020 as _

Cross reference number

ZEXEL 101441-9690 1014419690

Zexel num

Bosch num

Firm num

Name

101441-9690

INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE

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

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 2.15 2.1 2.2

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 11.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 42.8 41.8 43.8

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.6

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 43.4 41.9 44.9

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 4.7 4.2 5.2

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Set idle sub-spring (4)Main spring setting
----------
K=17 RAL=14+-0.1mm
----------

Speed control lever angle

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

----------
a=(35deg)+-5deg b=(33deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=8mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=900r/min r2=900r/min r3=900r/min r4=- r5=- r6=- Q1=- Q2=42.8+-1mm3/st Q3=- Q4= Q5= Q6= c1=- c2=+-4% c3=- c4=- c5=- c6=- a7=36 a8=35 a9=34 a10=33 a11=32 a12=31 a13=30 a14=29 a15=28 a16=27 a17=26 a18=25 a19=24 a20=23 a21=22 a22=21 a23=20 a24=19 a25=18 a26=17 a27=- a28=- r7=1800r/min r8=1750r/min r9=1700r/min r10=1650r/min r11=1600r/min r12=1550r/min r13=1500r/min r14=1450r/min r15=1400r/min r16=1350r/min r17=1300r/min r18=1250r/min r19=1200r/min r20=1150r/min r21=1100r/min r22=1050r/min r23=1000r/min r24=950r/min r25=900r/min r26=850r/min r27=- r28=- R7=1935+-45r/min R8=1880+-43r/min R9=1825+-42r/min R10=1770+-41r/min R11=1720+-40r/min R12=1665+-38r/min R13=1610+-37r/min R14=1555+-36r/min R15=1505+-35r/min R16=1450+-33r/min R17=1395+-32r/min R18=1340+-31r/min R19=1290+-30r/min R20=1235+-28r/min R21=1180+-27r/min R22=1130+-26r/min R23=1075+-25r/min R24=1020+-23r/min R25=965+-22r/min R26=915+-22r/min R27=- R28=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(100deg)

Information:

Test Procedure
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.
Illustration 1 g00563535
Diagram of the LED indicators
Illustration 2 g00562937
Functional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Connect the power supply.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Check the line voltage.
Reconnect the power supply.
Measure the line voltage at the terminals.
Verify the voltage of the power supply. The power supply voltage should be measured between 21.0 VDC and 28.0 VDC.The results of the preceding procedure are in the following list:
The line voltage is in the range. Proceed to 3.
The line voltage is out of the range. Refer to Troubleshooting, "System Power". Stop.
Attempt to operate the processor in the "RUN" mode.
Place the switch in the RUN position.The results of the preceding procedure are in the following list:
The processor enters the "RUN" mode. The processor resumes normal operation. Stop.
The processor will not enter the "RUN" mode. Proceed to 4.
Check the processor.
To avoid damage to electronic components, do not remove the processor from the SLC 5/04 Chassis until all power is removed from the power supply.Do not expose memory modules to surfaces or areas that may typically hold an electrostatic charge.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Remove the processor from the chassis.
Install the processor in another chassis.
Connect the power supply.
Configure the power supply.
Attempt to operate the processor in the "RUN" mode.The results of the preceding procedure are in the following list:
The processor enters the "RUN" mode. The processor will not perform functions in the run mode. Replace the chassis. Verify that the repair solves the problem. Stop.
The processor will not enter the "RUN" mode. Replace the processor. Refer to Maintenance Procedure, "Processor - Replace".