Information injection-pump assembly
ZEXEL
101606-9302
1016069302
Rating:
Cross reference number
ZEXEL
101606-9302
1016069302
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
131424-5120
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.5
4.45
4.55
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
9.6
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
112
109.2
114.8
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.5
15.7
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
112
111
113
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.6)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
113.5
111
116
Difference in delivery
mm3/st.
9
9
9
Fixing the lever
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1150
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Excess fuel setting for starting: SXL (N = N1)
(5)Damper spring setting
----------
RT=1 TH=1.9mm SXL=(R1+0.3)+0.2mm N1=350r/min
----------
----------
RT=1 TH=1.9mm SXL=(R1+0.3)+0.2mm N1=350r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=1deg+-5deg
----------
----------
a=1deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=18.5deg+-3deg b=25deg+-5deg
----------
----------
a=18.5deg+-3deg b=25deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=54deg+-5deg b=71deg+-5deg
----------
----------
a=54deg+-5deg b=71deg+-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=325r/min Ra=7.3+-0.1mm
----------
----------
N1=325r/min Ra=7.3+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(7deg)
----------
aa=15deg
----------
a=(7deg)
Information:
1. Disconnect fuel line (1) from the fuel transfer pump. Disconnect fuel line (2) from the fuel injection pump housing. Remove line (3) from the rack actuator package and aftercooler housing.2. Disconnect fuel injection lines (4) from the fuel injection pump housing.
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
3. Loosen the bleed valves, and release the air pressure in the air tank.4. Remove air line (5). Remove coolant line (6). 5. Disconnect wiring harness from bracket (7). Disconnect wires at connectors (8). 6. The weight of the fuel injection pump housing and rack actuator package is approximately 57 Kg (125 lb.). Attach a hoist to the full injection pump housing and remove bolts (9). 7. Remove two nuts (one shown) and two bolts (10). Remove bolt (11). Remove the fuel injection pump housing and rack actuator package (12).
Typical Example8. Remove o-ring seals (13) from the fuel injection pump housing. Install Fuel Injection Pump Housing And Rack Actuator Package
1. Attach a hoist to the fuel injection pump housing and rack actuator package (12). Be sure that the three O-ring seals are in position in the fuel injection pump housing. Install the fuel injection pump housing and rack actuator package on the timing gear housing. 2. Connect the wires at connectors (8).3. Connect wiring harness to bracket (7). 4. Install air line (5) and coolant line (6).5. Connect fuel injection lines (4) to the fuel injection pump housing. Tighten the fuel injection line nut to a torque of 40 7 N m (30 5 lb.ft.) with tool (A).6. Connect the fuel line (1) to the fuel transfer pump. Connect fuel line (2) to the fuel injection pump housing. Install line (3) to the rack actuator package and aftercooler housing. For timing of the fuel injection pump, see Install Timing Advance Unit.End By:a. install timing advance unit.
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
3. Loosen the bleed valves, and release the air pressure in the air tank.4. Remove air line (5). Remove coolant line (6). 5. Disconnect wiring harness from bracket (7). Disconnect wires at connectors (8). 6. The weight of the fuel injection pump housing and rack actuator package is approximately 57 Kg (125 lb.). Attach a hoist to the full injection pump housing and remove bolts (9). 7. Remove two nuts (one shown) and two bolts (10). Remove bolt (11). Remove the fuel injection pump housing and rack actuator package (12).
Typical Example8. Remove o-ring seals (13) from the fuel injection pump housing. Install Fuel Injection Pump Housing And Rack Actuator Package
1. Attach a hoist to the fuel injection pump housing and rack actuator package (12). Be sure that the three O-ring seals are in position in the fuel injection pump housing. Install the fuel injection pump housing and rack actuator package on the timing gear housing. 2. Connect the wires at connectors (8).3. Connect wiring harness to bracket (7). 4. Install air line (5) and coolant line (6).5. Connect fuel injection lines (4) to the fuel injection pump housing. Tighten the fuel injection line nut to a torque of 40 7 N m (30 5 lb.ft.) with tool (A).6. Connect the fuel line (1) to the fuel transfer pump. Connect fuel line (2) to the fuel injection pump housing. Install line (3) to the rack actuator package and aftercooler housing. For timing of the fuel injection pump, see Install Timing Advance Unit.End By:a. install timing advance unit.