101401-9380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019380


101401-9380 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101401-9380 1014019380

Cross reference number

ZEXEL 101401-9380 1014019380


Zexel num
Bosch num
Firm num
Name
101401-9380 
101401-9381 
 
  DPICO
INJECTION-PUMP ASSEMBLY
4D31T * 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   131424-6220
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   11.3
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   69 68 70
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.   10 8.7 11.3
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.3)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   69 68 70
Basic   *
Fixing the lever   *
Boost pressure kPa   93.3 93.3
Boost pressure mmHg   700 700
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.6
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   91 87 95
Fixing the lever   *
Boost pressure kPa   93.3 93.3
Boost pressure mmHg   700 700
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-1.1
Pump speed r/min   680 680 680
Average injection quantity mm3/st.   35 31 39
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-1.1
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   25 21 29
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   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   700 700 700
Rack position   R2-1.1
Boost pressure kPa   26.7 25.4 28
Boost pressure mmHg   200 190 210
Boost compensator adjustment_02
Pump speed r/min   700 700 700
Rack position   R2(R1-0. 3)
Boost pressure kPa   80 73.3 80
Boost pressure mmHg   600 550 600
Timer adjustment
Pump speed r/min   1350--
Advance angle deg.   0 0 0
Load   3/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1300
Advance angle deg.   0.3
Load   3/4
Timer adjustment_03
Pump speed r/min   1700
Advance angle deg.   4.5 4 5
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9380
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=J83 BCL=1.1+-0.1mm
----------

Speed control lever angle

Test data 101401-9380
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(44deg)+-3deg

Stop lever angle

Test data 101401-9380
N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at delivery) (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 (non-injection rack position). Confirm non-injection. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=(8)mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

0000001501 ACTUATOR

Test data 101401-9380
(a) Screw (B) Nut Bolt c (d) Speed lever (e) Actuator shaft 1. Actuator adjustment procedure (1)Position the speed lever (d) in the idle position. (2)Set bolt (c) so that the clearance between the speed lever (d)'s pin and the actuator shaft (e) is approximately L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1 and read the rack position when negative pressure P1 is applied to the actuator. (5)Gradually loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Apply negative pressure several times and confirm that the lever (d) returns to the idle position at negative pressure '0.' (7)Confirm that rack position is R2 when negative pressure is P2.
----------
L1=2mm N1=500r/min P1=66.7kPa(500mmHg) N2=500r/min R1=9.1mm P2=66.7kPa(500mmHg) R2=9.1mm
----------

Timing setting

Test data 101401-9380
(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)




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101401-9380  

101401-9381 
 
 
INJECTION-PUMP ASSEMBLY
4D31T
 
 
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4D31T
 
 
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INJECTION-PUMP ASSEMBLY
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INJECTION-PUMP ASSEMBLY
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