101606-6981 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066981

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101606-6981 1016066981

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Service parts 101606-6981 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8220

3. GOVERNOR 105931-6791

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-0660

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7130

11. Nozzle and Holder ME076614

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-4290

14. NOZZLE

105015-8470

15. NOZZLE SET

Include in #1:

101401-7223 as _

101401-7224

101606-6981 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101606-6981 1016066981

Zexel num

Bosch num

Firm num

Name

101606-6981

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

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

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 95.5 92.6 98.4

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. 10.1 8.6 11.6

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 95.5 94.5 96.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 101.5 97.5 105.5

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 99.7 95.7 103.7

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.6

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 102.5 98.5 106.5

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_07

Adjusting point I

Rack position 13.5+-0. 1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 65 105

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-1.3

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2-0.85

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position R2(R1+0. 6)

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1225

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 3 2.5 3.5

Remarks
Finish

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: RAL (4)Boost compensator stroke: BCL
----------
T1=F06 RAL=13.5+-0.1mm BCL=1.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(40deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
----------
aa=50mm bb=1350r/min cc=6.5-0.5mm
----------
a=25deg+-5deg b=27deg+-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=400r/min Ra=9.2+-0.1mm
----------

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=12deg
----------
a=(1deg)

Information:

1. Disconnect the batteries. 2. Remove top panel (1), front panel (2) and the rear panel from the enclosure. 3. Remove the bolt holding ground wires (5) to the frame. Remove wire ties (4) to separate the ground wires. Remove two screws and cover (3). 4. Remove three bolts (7) to disconnect the power bars from the main circuit breaker. Remove the insulation material from power bar (6). Remove bolts (8) holding ground bar (9) to the panel. Put identification on the wires for assembly purposes.5. Disconnect wires (10) from the terminal strip. Disconnect wires (11) from the voltage regulator. 6. Disconnect wires (12) from the inside of the control panel. 7. Remove bolts (13) and disconnect the small gage wire from each power bar. 8. Disconnect wire loom (14) from the generator housing and from the inside of the enclosure at three places. Remove the bolts and lower panel (15). Be sure all wires are free from the enclosure 9. Attach tooling (A) and a hoist to the enclosure as shown. Remove four bolts that fasten the enclosure to the base. Remove the enclosure. The weight of the enclosure is 1258 kg (570 lb.). The following steps are for the installation of the control panel enclosure.10. Use a hoist and tooling (A) to put the enclosure in position on the base. Install the four bolts that hold it to the base.11. Connect wire loom (14) to the generator housing and to the inside of the enclosure at three places. Install lower panel (15).12. Connect small gage wire to each power bar with bolts (13).13. Connect wires (12) to the inside of the control panel.14. Connect wires (10) to the terminal strip. Connect wires (11) to the voltage regulator.15. Connect ground bar (9) to the panel with two bolts (8). Wrap insulation material around power bar (6). Connect the power bars to the main circuit breaker with three bolts (7).16. Connect ground wires (5) to the frame and install wire ties (4) to hold the wires together. Install cover (3) with two screws.17. Install the rear, front and top panels on the enclosure.18. Connect the batteries.Remove Control Panel Enclosure (Standby)
The photographs shown are of a 3306B Standby Generator. The procedure is the same for the 3406B Standby Generator. 1. Remove door (1).2. Remove two bolts (2) from cover (3). 3. Remove doors (4).4. Remove fourteen bolts (7) and cover (5).5. Remove the battery charger. See the topic, Remove And Install Battery Charger.6. Remove the bolts and cover (6).7. Remove the three bolts located above the control panel and remove cover (3). 8. Identify and disconnect all the wires from breaker (9) and grounding buss (10).9. Remove bolts (8), bracket (11), and breaker (9). 10. Identify and disconnect all wires (12) between the generator and the control panels from the terminal strips on the control panels.11. Identify and disconnect all wires between the engine and control panels from the terminal strips on the control panels.12. Remove bolts (13). 13.