Information injection-pump assembly
ZEXEL
101603-6220
1016036220
Rating:
Cross reference number
ZEXEL
101603-6220
1016036220
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
3.3
3.25
3.35
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
11
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
65
63
67
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
R1(11)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
65
64
66
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11)
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
77.5
75.5
79.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1(11)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
51.5
49.5
53.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
14.1+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
0.8
Timer adjustment_04
Pump speed
r/min
1200
Advance angle
deg.
2.6
2.1
3.1
Timer adjustment_05
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=A10
----------
----------
T1=A10
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=40.5deg+-3deg
----------
----------
a=18.5deg+-5deg b=40.5deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at speed = rated point and rack position = aa (non-injection rack position). Confirm non-injection.
(2)After setting the stopper bolt , confirm non-injection at pump speed bb. Rack position = cc (non-injection rack position).
(3)Rack position = approximately dd
(4)Free (at shipping)
----------
aa=(5.4)mm bb=275r/min cc=(7.4)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
----------
aa=(5.4)mm bb=275r/min cc=(7.4)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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
----------
0000001601 ACS
(A) Housing
(B) Snap ring
(C) adjusting screw
(D) Set screw
(E): Push rod
(F) Spacer
1. Adjustment of the aneroid compensator
(1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1.
(2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2.
(3)(C) Turn the screw to adjust the beginning of aneroid compensator operation.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Adjust using screw C to obtain the performance shown in the graph above.
(3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=850r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11)mm Rb=R1-0.3mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=79.4kPa(596mmHg) Q1=65+-1cm3/1000st Q2=(59)cm3/1000st
----------
N1=850r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11)mm Rb=R1-0.3mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=79.4kPa(596mmHg) Q1=65+-1cm3/1000st Q2=(59)cm3/1000st
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=13deg
----------
a=(0deg)
----------
aa=13deg
----------
a=(0deg)
Information:
Use the following tests for troubleshooting and repair steps. Use the ""Test for Cylinder Cutout"" in order to determine if the replacement of individual injectors is needed. Replace suspect injectors with the part number of the original injector. Use the ""Test for Leakage from Poppet Valve"" in order to determine if the full set of injectors need to be replaced. For replacement of the full set of injectors, use the current injectors and new software that is listed in Table 2.Test for Cylinder Cutout
The cylinder cutout test should be used in order to determine if an individual injector may have caused the failure.
Warm the engine out of cold mode.
Connect Cat ET to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm 125 rpm. An extremely rough running engine will need to be diagnosed by other methods.
Cut out one bank of cylinders. Note engine rpm and the fuel position on the Cat ET screen at that time.
Cut out one of the remaining cylinders from the cylinder bank that is running. Allow the engine to stabilize, and note the fuel position.
Give power back to that cylinder. Allow the engine to stabilize. Note the fuel position.
Repeat steps 5 through 6 until the cylinder bank has been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps 5 through 8.
Repeat steps 4 through 9 with the engine at 2000 rpm.
Compare the results from the fuel position from each cylinder.
If the cylinder was cut out and the fuel position did not change the cylinder may not have been producing power. This cylinder would be suspect.
When you are finished with the test, reduce engine RPM to low idle. Shut off the engine.
Replace any suspect injector with a similar original injector. Install new seals for the injector and the jumper tube during this repair. The repair procedure for the injector is found in Special Instruction, REHS0116.It is possible that multiple injectors are functioning improperly. Complete ""Test for Leakage from Poppet Valve"" in order to evaluate possible excessive leakage from the injectors.Test for Leakage from Poppet Valve
Warm the engine out of Cold Mode to normal operating temperature.
Turn off the engine.
Remove the valve cover bolts in preparation in order to observe the injectors. Leave the covers in place.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with no load.
Use Cat ET in order to perform the test that overrides the injection actuation system. Increase injection actuation pressure to the maximum value.
Observe all of the injectors under each valve cover for leakage at the spill port. A small amount of dripping is acceptable. However, a continuous stream of oil is an indication of excessive leakage of the poppet valve. Only leaks at the spill port are an indication of excessive leakage from the poppet valve.
If multiple injectors display excessive leakage from the poppet valves, update the set of injectors with
The cylinder cutout test should be used in order to determine if an individual injector may have caused the failure.
Warm the engine out of cold mode.
Connect Cat ET to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm 125 rpm. An extremely rough running engine will need to be diagnosed by other methods.
Cut out one bank of cylinders. Note engine rpm and the fuel position on the Cat ET screen at that time.
Cut out one of the remaining cylinders from the cylinder bank that is running. Allow the engine to stabilize, and note the fuel position.
Give power back to that cylinder. Allow the engine to stabilize. Note the fuel position.
Repeat steps 5 through 6 until the cylinder bank has been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps 5 through 8.
Repeat steps 4 through 9 with the engine at 2000 rpm.
Compare the results from the fuel position from each cylinder.
If the cylinder was cut out and the fuel position did not change the cylinder may not have been producing power. This cylinder would be suspect.
When you are finished with the test, reduce engine RPM to low idle. Shut off the engine.
Replace any suspect injector with a similar original injector. Install new seals for the injector and the jumper tube during this repair. The repair procedure for the injector is found in Special Instruction, REHS0116.It is possible that multiple injectors are functioning improperly. Complete ""Test for Leakage from Poppet Valve"" in order to evaluate possible excessive leakage from the injectors.Test for Leakage from Poppet Valve
Warm the engine out of Cold Mode to normal operating temperature.
Turn off the engine.
Remove the valve cover bolts in preparation in order to observe the injectors. Leave the covers in place.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with no load.
Use Cat ET in order to perform the test that overrides the injection actuation system. Increase injection actuation pressure to the maximum value.
Observe all of the injectors under each valve cover for leakage at the spill port. A small amount of dripping is acceptable. However, a continuous stream of oil is an indication of excessive leakage of the poppet valve. Only leaks at the spill port are an indication of excessive leakage from the poppet valve.
If multiple injectors display excessive leakage from the poppet valves, update the set of injectors with