101607-6090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6090 1016076090

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Cross reference number

ZEXEL 101607-6090 1016076090

Zexel num

Bosch num

Firm num

Name

101607-6090

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 11.7

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 77.8 75.5 80.1

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 800 800 800

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.8 76.8 78.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 88.7 84.7 92.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 56.3 52.3 60.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1080

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1390

Advance angle deg. 6 5.5 6.5

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
----------
T1=H34
----------

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:Engine manufacturer's normal use 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). (3)Rack position = approximately ee. (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-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=10deg
----------
a=(3deg)

Information:

Control System PLC Outputs Hardwired to Relay Logic (Not Available to Customer)
Table 10
ISA TAG # PLC CARD # OUTPUT DESCRIPTION PLC REG ASSIGN SIGNAL TYPE ALARM SHUT DOWN TRIP / ACTIVATION CONDITION COMMENTS
YC-001 PLC07 Air Start to Engine O:7.0/03 DIGITAL Remote Start Only
YC-002 PLC07 Fuel Shutoff Signal to Engine O:7.0/00 DIGITAL X Shutdown or Fuel Off RFCR Relay
YC-015 PLC07 Air Shutoff Signal to Engine O:7.0/02 DIGITAL Overspeed and E-Stop ASOS Solenoid
YC-003 PLC07 Engine Prelube Signal to Engine O:7.0/01 DIGITAL >
9 kPa (1.3 psi) RPR Relay
YC-008 PLC07 Engine Protection System Override Relay On I:2.0/07 DIGITAL ROVR Relay - Override Shutdowns
YC-009 PLC07 Summary Group Alarm Relay Active O:7.0/05 DIGITAL X Any Alarm RSA Relay
YC-010 PLC07 Summary group Shutdown Signal O:7.0/07 DIGITAL X Protective Shutdown Energizes REFR Relay on Protective Shutdown
LY-001 PLC02 Jacket Water Detection Relay I:2.0/12 DIGITAL X RJWDA Relay Control System Lights and Meters
Table 11
ISA TAG # PLC CARD # OUTPUT DESCRIPTION PLC REG ASSIGN SIGNAL TYPE ALARM SHUT DOWN TRIP / ACTIVATION CONDITION COMMENTS
SI-004 Engine Speed Tachometer FREQ Mag Piclup Driven
SS1-001 Engine Hour Meter DIGITAL
PI-023 Starting Air Pressure Meter OHMS Resistive Sensor
YAL-009 PLC07 Summary Alarm Light O:7.0/06 DIGITAL X Any Alarm
YAL-010 PLC07 Summary Shutdown Light O:7.0/07 DIGITAL X Protective Shutdown
YAL-015 PLC07 PLC Failure O:7.0/15 DIGITAL X No Signal to RPLCFA RPLCFA De-energized on PLC Failure
PIL-008 Engine Prelubed DIGITAL >
9 kPa (1.3 psi)