Information injection-pump assembly
ZEXEL
101601-9690
1016019690
Rating:
Cross reference number
ZEXEL
101601-9690
1016019690
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
Overflow valve
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.6
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
59.5
57.9
61.1
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
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.5
7.7
11.3
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(11.6)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
59.5
58.5
60.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
71.8
68.6
75
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.2
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
84
80
88
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
84
84
94
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=A99
----------
----------
T1=A99
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=26.5deg+-5deg b=40deg+-3deg
----------
----------
a=26.5deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=40deg+-5deg
----------
----------
a=20deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Functional Test
PC-33: Injector Solenoids Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-34: +5V Sensor Voltage Supply Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-35: Engine Sensor Open or Short Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-36: Injection Actuation Pressure Sensor Test
System Operation
Schematic Diagnostic Codes
Functional Test
PC-37: Injection Actuation Pressure Control Valve Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-38: Injection Actuation Pressure System Test
System Operation
Diagnostic Codes
Functional Test
PC-39: Inlet Air Heater Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Inlet Air Heater Operation Chart (Personality Modules before JUN97) Inlet Air Heater Operation Chart (JUN97 and later Personality Modules) Functional Test
PC-40: Event Codes Test
System Operation
Diagnostic Codes
Functional Test
PC-33: Injector Solenoids Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-34: +5V Sensor Voltage Supply Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-35: Engine Sensor Open or Short Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-36: Injection Actuation Pressure Sensor Test
System Operation
Schematic Diagnostic Codes
Functional Test
PC-37: Injection Actuation Pressure Control Valve Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Functional Test
PC-38: Injection Actuation Pressure System Test
System Operation
Diagnostic Codes
Functional Test
PC-39: Inlet Air Heater Circuit Test
System Operation
Schematic ECM Pin Locations Diagnostic Codes
Inlet Air Heater Operation Chart (Personality Modules before JUN97) Inlet Air Heater Operation Chart (JUN97 and later Personality Modules) Functional Test
PC-40: Event Codes Test
System Operation
Diagnostic Codes
Functional Test