Information injection-pump assembly
ZEXEL
101601-5261
1016015261
Rating:
Service parts 101601-5261 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236001840A
12.
Open Pre:MPa(Kqf/cm2)
14.7(150)/19.6(200)
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-5261
1016015261
Zexel num
Bosch num
Firm num
Name
101601-5261
INJECTION-PUMP ASSEMBLY
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
Overflow valve
131424-5720
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
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
1-4-2-6-
3-5
Pre-stroke
mm
3.1
3.07
3.13
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
57.9
55.9
59.9
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
H
Rack position
8.3+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
5.3
3.8
6.8
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(10.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
57.9
56.9
58.9
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10.1)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
63.9
59.9
67.9
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.
40.3
36.3
44.3
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1(10.1)
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
63.7
59.7
67.7
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
E
Rack position
R1+0.45
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
39.9
35.9
43.9
Fixing the lever
*
Injection quantity adjustment_08
Adjusting point
I
Rack position
15+-0.5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
108
108
118
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1330--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1280
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4.5
4.2
4.8
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=C11
----------
----------
T1=C11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=46deg+-5deg b=(47deg)+-3deg
----------
----------
a=46deg+-5deg b=(47deg)+-3deg
Stop lever angle
N:Engine normal (pump normal)
S:Engine stop
(1)At speed = aa, temporarily set the stopper screw so that the rack = bb.
(2)Further turn the stop screw cc (dd turns) in the stop direction and set (rack position = ee).
(3)After setting, apply red paint.
----------
aa=1500+50+40r/min bb=5.7mm cc=1.5mm dd=1.5 ee=(3.7)mm
----------
a=20deg+-5deg b=(28deg)+-5deg
----------
aa=1500+50+40r/min bb=5.7mm cc=1.5mm dd=1.5 ee=(3.7)mm
----------
a=20deg+-5deg b=(28deg)+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
This engine may be equipped with a 12 or 24 volt starting system. Use only equal voltage for boost starting. The use of a welder or higher voltage will damage the electrical system.
Charging System Components
Alternator
The alternator is driven by belts from the crankshaft pulley. This alternator is a three phase, self-rectifying charging unit, and the regulator is part of the alternator.The alternator design has no need for slip rings or brushes, and the only part that has movement is the rotor assembly. All conductors that carry current are stationary. The conductors are: the field winding, stator windings, six rectifying diodes, and the regulator circuit components.The rotor assembly has many magnetic poles like fingers with air space between each opposite pole. The poles have residual magnetism (like permanent magnets) that produce a small amount of magnet-like lines of force (magnetic field) between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings from the small magnetic lines of force made by the residual magnetism of the poles. This AC current is changed to direct current (DC) when it passes through the diodes of the rectifier bridge. Most of this current goes to charge the battery and to supply the low amperage circuit, and the remainder is sent on to the field windings. The DC current flow through the field windings (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force now increase the amount of AC current produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator.The voltage regulator is a solid state (transistor, stationary parts) electronic switch. It feels the voltage in the system and switches on and off many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output.
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.
Alternator Components
(1) Regulator. (2) Roller bearing. (3) Stator winding. (4) Ball bearing. (5) Rectifier bridge. (6) Field winding. (7) Rotor assembly. (8) Fan.Starting System Components
Solenoid
Typical Solenoid SchematicA solenoid is a magnetic switch that does two basic operations.a. Closes the high current starter motor circuit with a low current start switch circuit.b. Engages the starter motor pinion with the ring gear.The solenoid switch is made of an electromagnet (one to two sets of windings) around a hollow cylinder. There is a plunger (core) with a spring load inside the cylinder that can move forward and backward. When the start switch is closed and electricity is sent through the windings, a magnetic field is made that pulls the plunger forward in the cylinder. This moves the shift lever (connected to the rear of the plunger) to engage the pinion
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101601-5261
INJECTION-PUMP ASSEMBLY