Information injection-pump assembly
ZEXEL
101603-6080
1016036080
Rating:
Service parts 101603-6080 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME035749
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101603-6080
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-6872
as _
Cross reference number
ZEXEL
101603-6080
1016036080
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
131424-5520
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
12.1
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
88
85.4
90.6
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
275
275
275
Each cylinder's injection qty
mm3/st.
10.5
9
12
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R(12.1)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
88
87
89
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.2
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
92
90
94
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.7
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
68.5
66.5
70.5
Fixing the lever
*
Boost pressure
kPa
28.7
28.7
28.7
Boost pressure
mmHg
215
215
215
Injection quantity adjustment_06
Adjusting point
I
Rack position
13.9+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-1.1
Boost pressure
kPa
19.3
19.3
19.3
Boost pressure
mmHg
145
145
145
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1-0.7
Boost pressure
kPa
28.7
27.4
30
Boost pressure
mmHg
215
205
225
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(12.1)
Boost pressure
kPa
45.3
38.6
52
Boost pressure
mmHg
340
290
390
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
1300
Advance angle
deg.
1.6
1.1
2.1
Timer adjustment_04
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=A08 BCL=1.1+-0.05mm
----------
----------
T1=A08 BCL=1.1+-0.05mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=33deg+-5deg b=41deg+-3deeg
----------
----------
a=33deg+-5deg b=41deg+-3deeg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Free (at shipping)
(2)Rack position = approximately aa.
(3)Set the stopper bolt at speed = rated point and rack position = bb. Confirm non-injection.
(4)After setting the stopper bolt, confirm non-injection at speed = cc and rack position = dd.
----------
aa=17.4mm bb=(6)mm cc=275r/min dd=(8.5)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
----------
aa=17.4mm bb=(6)mm cc=275r/min dd=(8.5)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=400+-5r/min Ra=9.2mm
----------
----------
N1=400+-5r/min Ra=9.2mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
Information:
Illustration 1 g02004767
(1) Ring for Identification (2) 228-7094 O-Ring Seal (3) 345-3399 Injector Sleeve An oversized injector sleeve will be introduced in order to improve the life cycle of the cylinder heads. The new sleeve has an oversized outside diameter, which does not allow the injector sleeve to fit the standard bore. The oversized sleeve will have an added ring that is located around the middle of the insert for identification. Also, the new sleeve will require a larger bottom O-ring. Refer to Illustration 1.
Illustration 2 g02004793
(4) Identification markThe remanufactured cylinder head has an identification mark that is located on the top of the cylinder head. This mark indicates the cylinders that have the oversized inserts.