Information injection-pump assembly
ZEXEL
101607-6692
1016076692
Rating:
Cross reference number
ZEXEL
101607-6692
1016076692
Zexel num
Bosch num
Firm num
Name
101607-6692
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
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
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.
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
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
----------
----------
T1=J61
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=42deg+-3deg
----------
----------
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
----------
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
----------
----------
b=42deg+-3deg c=18.5deg+-5deg
0000001601 RACK SENSOR
V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------
0000001701 MICRO SWITCH
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
1. Microswitch adjustment (OPEN type)
Confirm with the lever angle at full.
(1)Speed N1
(2)Rack position Ra
2. Idle side microswitch adjustment (OPEN type)
Confirm with the lever angle at idle.
(1)Speed N2
(2)Rack position Rb
----------
N1=1675r/min Ra=8.5+-0.1mm N2=275r/min Rb=9.7+-0.1mm
----------
----------
N1=1675r/min Ra=8.5+-0.1mm N2=275r/min Rb=9.7+-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=8.5deg
----------
a=(3deg)
----------
aa=8.5deg
----------
a=(3deg)
Information:
Proper oil viscosity AND oil type/specification are required to maximize machine compartment performance and life. Do NOT use only oil viscosity, or only oil type to determine the machine compartment oil selection. Using only the oil viscosity or only the oil type to determine a machine compartment oil selection can lead to reduced performance and compartment failure. Refer to the "Lubricant Viscosities for Ambient Temperatures" tables and to ALL of the associated footnotes.
In colder ambient conditions a machine warm-up procedure and/or supplemental machine fluid compartment heat may be required. Machine specific warm-up procedures can typically be found in the Operation and Maintenance Manual for the machine. In addition, generic machine warm-up procedures can be found in this Special Publication, "Procedures for Machines that are Used in Cold Weather - (Generic)" topic. Some of the "Lubricant Viscosities for Ambient Temperatures" tables in this Special Publication include footnotes that address compartment warm-up.
Not following the recommendations found in this Special Publication can lead to reduced performance and compartment failure.
Do NOT use only the oil viscosities when determining the recommended oil for an engine compartment. The oil type (specification) MUST also be used.
Note: Different brand oils may use different additive packages to meet the various engine performance category/specification requirements. For the best results, do not mix oil brands.Note: The availability of the various Cat oils will vary by region.The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation. Refer to Table 1 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.Refer to Table 1 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.If ambient temperature conditions at engine start-up require the use of multigrade SAE 0W oil, SAE 0W-40 viscosity grade is generally preferred over SAE 0W-30.Note: SAE 10W-30 is the preferred viscosity grade for the following diesel engines when the ambient temperature is above -18 °C (0 °F), and below 40 °C (104 °F).
C7
C-9
C9
3116
3126
Table 1
Lubricant Viscosities for Ambient Temperatures (1) (2)
Ambient Temperature
Viscosity Grade Minimum Maximum
SAE 0W-30
-40 °C (-40 °F)
30 °C (86 °F)
SAE 0W-40
-40 °C (-40 °F)
40 °C (104 °F)
SAE 5W-30
-30 °C (-22 °F)
30 °C (86 °F)
SAE 5W-40
-30 °C (-22 °F)
50 °C (122 °F)
SAE 10W-30 (3).
-18 °C (0 °F)
40 °C (104 °F)
SAE 10W-40
-18 °C (0 °F)
50 °C (122 °F)
SAE 15W-40
-9.5 °C (15 °F)
50 °C (122 °F)
( 1 ) Refer to this Special Publication, "Engine Oil" article for recommendations of diesel engine oil type.
( 2 ) Supplemental heat is recommended for
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101607-6692
INJECTION-PUMP ASSEMBLY