101607-6051 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076051

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6051 1016076051

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Service parts 101607-6051 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105931-9351

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5150

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7053

11. Nozzle and Holder ME076953

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET 105019-0220

Include in #1:

101402-7450 as _

101607-6051 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101607-6051 1016076051

Zexel num

Bosch num

Firm num

Name

101607-6051

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 131424-8420

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 12.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 101.8 98.7 104.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 600 600 600

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 101.8 100.8 102.8

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 117.9 113.9 121.9

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 4)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 92.6 88.6 96.6

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 113.5 109.5 117.5

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-0.75

Boost pressure kPa 3.3 2 4.6

Boost pressure mmHg 25 15 35

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 4)

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1340

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Boost compensator stroke: BCL
----------
T1=H52 BCL=0.75+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=42deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1350r/min bb=7-0.5mm cc=275r/min dd=(8)mm
----------
a=11.5deg+-5deg b=28deg+-5deg

0000001501 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=42deg+-3deg c=18.5deg+-5deg

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=11deg
----------
a=(1deg)

Information:

Test Procedure
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.The thermocouple module has five LED indicators. Four of the LED indicators are "Channel Status" indicators. The "Channel Status" indicators are numbered according to the channel. One of the LED indicators is a "Module Status" indicator. You can recover from the "Channel Status" errors.Diagnostics are displayed on the "Module Status" LED indicator. Operating errors are displayed on the "Module Status" LED indicator. Problems may be detected during powerup or problems may be detected during operation. When an error occurs the module will not communicate with the processor. The channel is disabled and the data is cleared.
Illustration 1 g00563580
Diagram of the LED indicators
Illustration 2 g00563584
Diagram of the thermocouple module
Illustration 3 g00563586
Schematic of the thermocouple moduleFunctional Test
The "Module Status" LED is on. The module is operating normally. Stop.
The "Channel Status" LED is on. The module is operating normally. Stop.
The "Module Status" LED is off. The module is in a fault condition. Proceed to 6.
The "Channel Status" LED is off. The channel is not enabled. This is normal if the sensor is not wired.
The "Channel Status" LED is blinking. The module is in a fault condition. Proceed to 10.
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 7.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Check the LED indicator on the module.
Connect the power supply.
Cycle the power to the module.The results of the preceding procedure are in the following list:
No errors are displayed on the LED indicators. Stop.
Errors are displayed on the LED indicators. Proceed to 8.
Check the module for a fault.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
To avoid potential damage to the processor, handle all modules by the ends of the carrier or edges of the plastic housing. Skin oil or dirt can corrode metallic surfaces, inhibiting electrical contact.
Disconnect the power supply.
Remove the module from the chassis.Reference: Maintenance