101401-9080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019080

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101401-9080 1014019080

Service parts 101401-9080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9750

3. GOVERNOR 105921-4980

4. SUPPLY PUMP

105220-6110

5. AUTOM. ADVANCE MECHANIS 105676-0770

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4120

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3070

14. NOZZLE

105017-0100

15. NOZZLE SET

Include in #1:

101401-9080 as INJECTION-PUMP ASSEMBLY

101603-2313 as _

101603-2314

Cross reference number

ZEXEL 101401-9080 1014019080

Zexel num

Bosch num

Firm num

Name

101401-9080

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 131424-6220

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.6 3.55 3.65

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 10.2+-0. 5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46 45 47

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 -

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.2)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46 45 47

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 60 56 64

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 37.7 33.7 41.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point D

Rack position R2+0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 30 26 34

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 100 100 100

Average injection quantity mm3/st. 67 67 72

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.3

Boost pressure kPa 20 18.7 21.3

Boost pressure mmHg 150 140 160

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.2)

Boost pressure kPa 29.3 22.6 29.3

Boost pressure mmHg 220 170 220

Timer adjustment

Pump speed r/min 1500--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1450

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1750

Advance angle deg. 4 3.5 4.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B88 BCL=0.3+-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=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less.
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

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=11deg
----------
a=(130deg)