101603-9650 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039650

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9650 1016039650

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Cross reference number

ZEXEL 101603-9650 1016039650

Zexel num

Bosch num

Firm num

Name

101603-9650

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 134424-1520

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.4

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 63 61.4 64.6

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. 9.2 7.4 11

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(11.4)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 63 62 64

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.65

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 84.5 80.5 88.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 58 54.8 61.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 82 82 92

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
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T1=E88
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
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N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=26.5deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=20deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Install the shim (D) to the rod (C) and tighten nut (E). (3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L. (4)Release the rack fixing and mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (-0420) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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L=33-0.2mm N1=1500r/min Ra=R1(11.4)+0.65mm
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Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(60deg)

Information:

1. Remove line (1) from the fuel ratio control. Remove two bolts (3), and remove solenoid (2) from the governor housing.2. Disconnect throttle linkage (4) from the lever assembly on the side of the governor housing. (A test application is shown in the photo.)3. Remove two bolts (5) from the front of the governor housing. Remove eight bolts (6), and remove governor housing (7). 4. Remove two bolts that hold fuel ratio control (8) to the governor housing. Unscrew the fuel ratio control from shaft (9) and remove it.5. Remove plug and seal (10) from the governor housing. 6. Remove two bolts (12) that hold lock (11) and flange (14) on fuel ratio control (8). Remove lock (11), flange (14), and O-ring seal (13) from the fuel ratio control.7. Check the condition of O-ring seal (13). If it is worn or damaged, make a replacement with a new part. 8. Remove ring (19) from the end of shaft (15). Remove lever assembly (18), spring (17), lever (16), spacer (21) and shaft (15) from the governor housing.9. Remove pin (20) from lever assembly (18) with a hammer and punch. Remove shaft (9) from the lever assembly. The following steps are for the installation of the fuel ratio control.10. Position shaft (9) in lever assembly (18) and install it with pin (20) using a hammer and punch.11. Install shaft (15), spacer (21), lever (16), spring (17) and lever assembly (18) in the governor housing. Install ring (19) on the end of shaft (15).12. Install O-ring seal (13) on fuel ratio control (8). Install flange (14) and lock (11) on the fuel ratio control with bolts (12).13. Install seal and plug (10) in the governor housing.14. Check the condition of the four O-ring seals on top of the governor housing where the fuel ratio control mounts. If any of the seals are worn or damaged, make a replacement with new parts.15. Screw fuel ratio control (8) onto shaft (9) approximately six turns. Install the fuel ratio control with the two bolts that hold it to the governor housing.16. Position governor housing (7), and install two bolts (5) on the front of the governor housing. Install eight bolts (6).17. Connect throttle linkage (4) to the lever assembly on the side of the governor housing.18. Install solenoid (2) with bolts (3). Install line (1) on the fuel ratio control.19. Make an adjustment to the fuel ratio control. See the topic, FUEL RATIO CONTROL ADJUSTMENT in the TESTING AND ADJUSTING section of this Module.