101607-6623 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076623

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6623 1016076623

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Cross reference number

ZEXEL 101607-6623 1016076623

Zexel num

Bosch num

Firm num

Name

101607-6623

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 11.6

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 75.5 73.2 77.8

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(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 75.5 74.5 76.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 82.5 78.5 86.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.35

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 52.5 48.5 56.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 115 135

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 1 0.5 1.5

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

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=J61
----------

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=7deg
----------
a=(3deg)

Information:

Illustration 1 g06084375
(A) 364-7654 Guardrail As
(B) 8T-4139 Bolt
(C) 5P-1076 Hard Washer
(D) 8T-4183 Bolt
(E) 7X-3392 Hard WasherUse the following rework procedure to remove Guardrail assembly
Removing guardrail assembly (A) by removing two 8T-4139 Bolt (B), two 5P-1076 Hard Washer (C), four 8T-4183 Bolt (D), and four 7X-3392 Hard Washer (E). Save the parts.
Illustration 2 g06084382
(F) 206-5017 Spacer
(G) 8T-4226 Plated Washer
(H) 8T-4136 Bolt
(J) 430-4507 Flap
(K) 9X-2045 Screw
(L) 9X-6381 Washer
(M) 398-2993 Tank Filler Cap
(N) 446-0473 Adapter As
(P) 430-4518 Tank Mounting Gp
Remove 430-4518 Tank Mounting Gp (P) by removing two 206-5017 Spacer (F), two 8T-4226 Plated Washer (G), two 8T-4136 Bolt (H), and 430-4507 Flap (J). Discard the parts.
Remove six 9X-2045 Screw (K), six 9X-6381 Washer (L), 398-2993 Tank Filler Cap (M), and 446-0473 Adapter As (N). Discard the parts.
Illustration 3 g06084449
(H) 8T-4136 Bolt
(R) 8T-4121 Hard Washer
(S) 430-4504 Plate
(T) 430-4510 Plate As
Remove two 8T-4136 Bolt (H), two 8T-4121 Hard Washer (R), and 430-4504 Plate (S) and discard the parts.
Remove two 8T-4136 Bolt (H), two 8T-4121 Hard Washer (R), and 430-4510 Plate As (T). Discard the parts.
Illustration 4 g06084463
(H) 8T-4136 Bolt
(R) 8T-4121 Hard Washer
(U) 365-0333 Hose
(V) 430-4505 Plate As
(W) 2J-6540 Hose Clamp
Remove Four 8T-4136 Bolt (H), four 8T-4121 Hard Washer (R), and 430-4505 Plate As (V). Discard the parts.
Remove 2J-6540 Hose Clamp (W), and 365-0333 Hose (U). Discard the parts.
Illustration 5 g06084515
(X) 451-2035 Tread
(1) 481-4103 Hose
(2) 2J-6540 Hose Clamp
Remove 451-2035 Tread (X) and save the part.
Install new 481-4103 Hose (1), 2J-6540 Hose Clamp (2), and 451-2035 Tread (X) that were saved in Step 8.
Illustration 6 g06084542
(3) 481-4102 Plate As
(4) 446-0473 Adapter As
(5) 9X-2045 Screw
(6) 9X-8256 Washer
(7) 8T-4136 Bolt
(8) 8T-4121 Hard Washer
(9) 481-4106 Angle As
Install new 481-4102 Plate As (3) by using 481-4106 Angle As (9), two 8T-4136 Bolt (7), and two 8T-4121 Hard Washer (8).
Install new 446-0473 Adapter As (4) by using six 9X-2045 Screw (5), and six 9X-8256 Washer (6).
Install new 2J-6540 Hose Clamp (2) to hose and adapter.
Illustration 7 g06084606
(7) 8T-4121 Hard Washer
(8) 8T-4136 Bolt
(10) 481-4104 Plate As
(11) 126-8472 Seal
(12) 205-3743 Hinge As
(13) 481-4108 Plate As
Install new 481-4108 Plate As (13) by using two 8T-4121 Hard Washer, and two 8T-4136 Bolt (8).
Install new 126-8472 Seal (11) on 481-4104 Plate As (10).
Install new 205-3743 Hinge As (12) by using four 8T-4121 Hard Washer, and four 8T-4136 Bolt (8) with 481-4104 Plate As (10), and 481-4108 Plate As (13) .
Illustration 8 g06084883
(14) 398-2993 Tank Filler Cap
(15) 387-5472 Lanyard
Install new 398-2993 Tank Filler Cap (14), and 387-5472 Lanyard (15).
Illustration 9 g06084916
(7) 8T-4121 Hard Washer
(8) 8T-4136 Bolt
(16) 481-4105 Plate
(17) 331-4030 Latch As
(18) 7Y-7389 Screw
Install new 331-4030 Latch As (17) by using three 7Y-7389 Screw (18).
Install new 481-4105 Plate (16) by using two 8T-4121 Hard Washer (7) and two 8T-4136 Bolt (8).
Illustration 10 g06084953
(19) 487-0512 Guardrail As
(B) 8T-4139 Bolt
(C) 5P-1076 Hard Washer
(D) 8T-4183