Information injection-pump assembly
ZEXEL
101607-6140
1016076140
Rating:
Cross reference number
ZEXEL
101607-6140
1016076140
Zexel num
Bosch num
Firm num
Name
101607-6140
INJECTION-PUMP ASSEMBLY
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
131424-8420
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
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
12
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
85.1
82.5
87.7
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(12)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
85.1
84.1
86.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.85
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
99.9
95.9
103.9
Fixing the lever
*
Injection quantity adjustment_05
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
1100
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
2.5
2.5
3.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
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=G43
----------
----------
T1=G43
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Accelerator lever
(2)Use the hole at R = aa
(3)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=41deg+-5deg b=(42deg)+-3deg
----------
aa=35mm
----------
a=41deg+-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=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm
----------
a=32.5deg+-5deg b=25deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm
----------
a=32.5deg+-5deg b=25deg+-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
----------
----------
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=10deg
----------
a=(3deg)
----------
aa=10deg
----------
a=(3deg)
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
A customer experienced an early hour failure of the injector harness. Incorrect harness routing allowed the wiring harness to contact the valve spring.Solution
Illustration 1 g02703456
If the harness (1) has contacted the valve spring (2), inspect the wiring for cuts or exposed wire. If the harness is cut or has exposed wiring, replace the harness. When the harness is torqued down, make sure that the harness clips stay straight. If the clips rotate when torqued, the harness could contact the valve spring. Refer to Illustration 1.
Illustration 2 g02703161
If the harness has contacted the valve spring but does not have any cuts or exposed wire, disconnect the injector connector. Rotate the connector 360 degrees away from the valve spring and reconnect the connector. This rotation should twist the wires slightly and pull the wires to the correct location. Refer to Illustration 2.
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
A customer experienced an early hour failure of the injector harness. Incorrect harness routing allowed the wiring harness to contact the valve spring.Solution
Illustration 1 g02703456
If the harness (1) has contacted the valve spring (2), inspect the wiring for cuts or exposed wire. If the harness is cut or has exposed wiring, replace the harness. When the harness is torqued down, make sure that the harness clips stay straight. If the clips rotate when torqued, the harness could contact the valve spring. Refer to Illustration 1.
Illustration 2 g02703161
If the harness has contacted the valve spring but does not have any cuts or exposed wire, disconnect the injector connector. Rotate the connector 360 degrees away from the valve spring and reconnect the connector. This rotation should twist the wires slightly and pull the wires to the correct location. Refer to Illustration 2.
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101607-6140
INJECTION-PUMP ASSEMBLY