101401-1670 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014011670

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101401-1670 1014011670

Cross reference number

ZEXEL 101401-1670 1014011670

Zexel num

Bosch num

Firm num

Name

101401-1670

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 131424-8820

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 11.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 65 63.4 66.6

Max. variation between cylinders % 0 -2.5 2.5

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 325 325 325

Average injection quantity mm3/st. 12 10.7 13.3

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(11.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 65 64 66

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.2

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 83.5 79.5 87.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 48.8 44.8 52.8

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.2

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 31.6 27.6 35.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-0.2

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-0. 1)

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 2.5 2 3

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)Boost compensator stroke: BCL
----------
T1=J10 BCL=0.2+-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=40mm
----------
a=26deg+-5deg b=(40deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=40mm
----------
a=33deg+-5deg b=40deg+-5deg

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=1025r/min Ra=8.5+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(130deg)