101697-9000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016979000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101697-9000 1016979000

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Service parts 101697-9000 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3980

3. GOVERNOR 105921-9730

4. SUPPLY PUMP

105220-7010

5. AUTOM. ADVANCE MECHANIS 105672-0360

6. COUPLING PLATE 105662-1380

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6350

11. Nozzle and Holder 16600-Z5601

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE

105015-8760

15. NOZZLE SET

Include in #1:

101697-9000 as INJECTION-PUMP ASSEMBLY

106871-7060 as _

Cross reference number

ZEXEL 101697-9000 1016979000

Zexel num

Bosch num

Firm num

Name

101697-9000

INJECTION-PUMP ASSEMBLY
FE6T

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 134424-1520

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 77.5 75.5 79.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 77.5 76.5 78.5

Basic *

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 91 87.8 94.2

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 3)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 68.5 65.3 71.7

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.6

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 54.5 52.5 56.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 84 84 104

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-0.6

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 3)

Boost pressure kPa 10 10 10

Boost pressure mmHg 75 75 75

Timer adjustment

Pump speed r/min 1170--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1120

Advance angle deg. 0.5

Load 3/4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.7 2.3

Load 4/4

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 (4)Boost compensator stroke: BCL
----------
T1=M95 BCL=0.6+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=26.5deg+-5deg b=44deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=42mm
----------
a=27deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1400r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=R3(R1+0.15)mm Rb=(R3-1.1)mm Pa=(77.3)+-2.7kPa((580)+-20mmHg) Pb=52.9+-0.7kPa(397+-5mmHg) Q1=(91)+-1.6cm3/1000st Q2=76.5+-3cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Test Procedure
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.The thermocouple module has five LED indicators. Four of the LED indicators are "Channel Status" indicators. The "Channel Status" indicators are numbered according to the channel. One of the LED indicators is a "Module Status" indicator.Diagnostics are displayed on the "Module Status" LED indicator. Operating errors are displayed on the "Module Status" LED indicator. Problems may be detected during powerup or problems may be detected during operation. When an error occurs, the module will not communicate with the processor. The channel is disabled and the data is cleared.
Illustration 1 g00563417
Diagram of the LED indicators
Illustration 2 g00563392
Diagram of the LED indicators
Illustration 3 g00563575
Diagram of the RTD module
Illustration 4 g00563579
Schematic of the RTD moduleFunctional Test
The "Module Status" LED is on. The module is operating normally. Stop.
The "Channel Status" LED is on. The module is operating normally. Stop.
The "Module Status" LED is off. The module is in a fault condition. Proceed to 6.
The "Channel Status" LED is off. The channel is not enabled. This is normal if the sensor is not wired.
The "Channel Status" LED is blinking. The module is in a fault condition. Proceed to 10.
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 7.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Check the LED indicator on the module.
Connect the power supply.
Cycle the power to the module.The results of the preceding procedure are in the following list:
No errors are displayed on the LED indicators. Stop.
Errors are displayed on the LED indicators. Proceed to 8.
Check the module for a fault.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
To avoid potential damage to the processor, handle all modules by the ends of the carrier or edges of the plastic housing. Skin oil or dirt can corrode metallic surfaces, inhibiting electrical contact.
Disconnect the power supply.
Remove the module from the chassis.Reference: Maintenance Procedure, "Input Module