101607-9520 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016079520

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-9520 1016079520

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Cross reference number

ZEXEL 101607-9520 1016079520

Zexel num

Bosch num

Firm num

Name

101607-9520

DPICO

INJECTION-PUMP ASSEMBLY
6D16 * Q

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 131424-5520

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 3.3 3.25 3.35

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 B

Rack position 10.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 51.7 50.7 52.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 71 61 81

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1200++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1200.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1.5 1.5 1.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Rack difference between N = N1 and N = N2
----------
K=16 N1=1200r/min N2=750r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=19deg+-5deg b=19deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=2.5deg+-5deg b=53deg+-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=18deg
----------
a=(2deg)

Information:

Installing the Red LED Lamp (Regeneration Disable Lamp)
Illustration 1 g02402796
242-3282 Led Lamp As Use 155-2269 Connector Plug As as a mating connector. 155-2269 Connector Plug As is not included in the kit. Also, 102-8802 Receptacle Kit contains 3E-3364 Receptacle and 3E-3365 Receptacle Lock Wedge .
Insert the red (power) wire from the 242-3282 LED Lamp As into terminal 1 of 3E-3364 Receptacle .
Insert the black (ground) wire from the LED lamp into terminal 2 of the receptacle.
Insert 3E-3365 Receptacle Lock Wedge is the receptacle.
Connect terminal 1 of the receptacle to terminal 13 of 160-7689 Connector Plug As .
Connect terminal 2 of the receptacle to the ground/return (-).Installing the Illuminated Plug (Regeneration Lamp)
Illustration 2 g02402326
332-1064 Illuminated Plug The terminal designations can be found on the sides of 332-1064 Illuminated Plug and 205-5471 Connector .
Connect terminal 1A of the connector to the battery power (+).
Connect terminal 2A of the connector to the battery power (+).
Connect terminal 1B of the connector to terminal 30 of the plug.
Connect terminal 2B of the connector to terminal 31 of the plug.
Crimp the 112-9611 Blade Terminal onto the wires necessary to create the connections described in the previous steps.
Insert the blade terminals into the appropriate terminal locations of the connector.
Connect the plug to the connector. The plug and the connector are mating connectors.Installing the Hydraulic Lockout Rocker Switch (High Speed Regeneration Rocker Switch)
Illustration 3 g02366857
284-3623 Rocker Switch The terminal designations can be found on the sides of the 223-4778 Connector Plug As .
Insert 288-7146 Wire As into terminals 2,3,5, and 9 of the plug.
Splice the unoccupied ends of two 288-7146 Wire As together. Insert the spliced wire to provide a connection for terminal 6 to terminal 7 of 223-4778 Connector Plug As .
Connect terminal 2 of 223-4778 Connector Plug As to terminal 18 of 160-7689 Connector Plug As .
Connect