Information injection-pump assembly
ZEXEL
101601-3450
1016013450
Rating:
Cross reference number
ZEXEL
101601-3450
1016013450
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4
3.95
4.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
86.1
85.1
87.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
44
44
Boost pressure
mmHg
330
330
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.4+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
15.5
14.3
16.7
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
9.9
Boost pressure
kPa
5.3
2.6
8
Boost pressure
mmHg
40
20
60
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.1
Boost pressure
kPa
30.7
30.7
30.7
Boost pressure
mmHg
230
230
230
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
1.5
1
2
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
3.2
2.7
3.7
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Boost compensator stroke
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=13 N1=1100r/min N2=750r/min N3=1100r/min N4=400r/min
----------
----------
K=13 N1=1100r/min N2=750r/min N3=1100r/min N4=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=6deg+-5deg b=20deg+-5deg
----------
----------
a=6deg+-5deg b=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
(2)Stopper bolt setting
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
Information:
1. Remove two bolts (1).2. Remove fuel ratio control and gasket.Install Fuel Ratio Control
1. Put gasket (2) in position. Make an alignment with the lever in the shutoff housing with the plunger in the fuel ratio control. control.2. Install fuel ratio control (1) and the bolts that hold it.Disassemble Fuel Ratio Control
start by:a) remove fuel ratio control1. Remove solenoid (1) from the fuel ratio control. 2. Remove bolts (3) and covers (2) and (4). Remove diaphragm (11) and piston (17). Remove gasket (16) from cover (4).
Spring force is present. Slowly loosen the two bolts to release the force.
3. Remove two bolts (5), cover (6) and spring (15).
Spring force is present. Hold diaphragm assembly in position and remove pin (14).
4. Remove pin (14) and slowly release the spring force.5. Remove spring (8) and bolt (7) from housing (12).6. Remove washer (10) and diaphragm (9) from retainer (13).Assemble Fuel Ratio Control
1. Assemble washer (3), diaphragm (2) and retainer (1).2. Install bolt (4) in housing (10).3. Install spring (5), diaphragm assembly (11) and pin (6) in housing (10).4. Install spring (22) in cover (7). Install cover (7) on housing (10) with the two bolts (16) that hold it. 5. Install gasket (13) on cover (8). Install piston (14) to cover (8). Install diaphragm (15) in cover (9). 6. Put covers (8) and (9) in position on cover (7) with the bolts that hold them.7. Install solenoid (17) on the fuel ratio control. end by:a) install fuel ratio control For adjustment of fuel ratio control, see TESTING AND ADJUSTING.
1. Put gasket (2) in position. Make an alignment with the lever in the shutoff housing with the plunger in the fuel ratio control. control.2. Install fuel ratio control (1) and the bolts that hold it.Disassemble Fuel Ratio Control
start by:a) remove fuel ratio control1. Remove solenoid (1) from the fuel ratio control. 2. Remove bolts (3) and covers (2) and (4). Remove diaphragm (11) and piston (17). Remove gasket (16) from cover (4).
Spring force is present. Slowly loosen the two bolts to release the force.
3. Remove two bolts (5), cover (6) and spring (15).
Spring force is present. Hold diaphragm assembly in position and remove pin (14).
4. Remove pin (14) and slowly release the spring force.5. Remove spring (8) and bolt (7) from housing (12).6. Remove washer (10) and diaphragm (9) from retainer (13).Assemble Fuel Ratio Control
1. Assemble washer (3), diaphragm (2) and retainer (1).2. Install bolt (4) in housing (10).3. Install spring (5), diaphragm assembly (11) and pin (6) in housing (10).4. Install spring (22) in cover (7). Install cover (7) on housing (10) with the two bolts (16) that hold it. 5. Install gasket (13) on cover (8). Install piston (14) to cover (8). Install diaphragm (15) in cover (9). 6. Put covers (8) and (9) in position on cover (7) with the bolts that hold them.7. Install solenoid (17) on the fuel ratio control. end by:a) install fuel ratio control For adjustment of fuel ratio control, see TESTING AND ADJUSTING.