101401-9400 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019400


101401-9400 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101401-9400 1014019400

Cross reference number

ZEXEL 101401-9400 1014019400


Zexel num
Bosch num
Firm num
Name
101401-9400 
 
  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   11.1
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   58 57 59
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(11.1)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   58 57 59
Basic   *
Fixing the lever   *
Boost pressure kPa   80 80
Boost pressure mmHg   600 600
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.6
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   83 79 87
Fixing the lever   *
Boost pressure kPa   80 80
Boost pressure mmHg   600 600
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-0.7
Pump speed r/min   680 680 680
Average injection quantity mm3/st.   34 30 38
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   D
Rack position   (R2-0.65 )
Pump speed r/min   550 550 550
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   *
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   R2-0.7
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   66.7 60 66.7
Boost pressure mmHg   500 450 500
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.   2.5 2 3
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9400
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 (5)Set idle at delivery.
----------
T1=L17 BCL=0.7+-0.1mm
----------

Speed control lever angle

Test data 101401-9400
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

Test data 101401-9400
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

Timing setting

Test data 101401-9400
(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=14deg
----------
a=(130deg)




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