101607-6341 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076341

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6341 1016076341

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Cross reference number

ZEXEL 101607-6341 1016076341

Zexel num

Bosch num

Firm num

Name

101607-6341

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

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 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 1450

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=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

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=13deg+-5deg b=0deg+-5deg c=(25deg)

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=10deg
----------
a=(1deg)

Information:

Disconnect all electrical power from the monitor before removing components. Failure to disconnect the power could result in severe electrical shock or damage to the monitor. An electrical shock can cause severe personal injury or death.
Choose the appropriate drive for your monitor from the table below. The 203-7811 Engine Monitoring Control Group uses Wonderware as the "Graphic Display Application". The 203-7810 Engine Monitoring Control Group uses RSView as the "Graphic Display Application".
Table 1
Drive "Graphic Display Application"
203-7816 Storage Drive RSView
204-8792 Storage Drive Wonderware In order to install the drive, perform the procedure that follows:
Connect the ribbon cable connector and power cables to the hard drive and the floppy disk drive.Note: Make sure that the ribbon cable is correctly installed. The connector must be positioned so that the red wire of the cable is closest to the back of the unit. If you are using the new cables, also connect the other end of the cables to the Central Processing Unit (CPU) card.
Illustration 1 g00858453
(1) Drive Bay Mounting Studs
Position the drive bay into the chassis so that the studs (1) on the chassis fit into the grommets on the drive bay.Note: Be careful not to push the vibration dampers (grommets) on the drive bay out of the sheet metal.
Install the back cover.
Apply power and verify the operation of the drive. Refer to any additional instructions that are provided with the drive.