101401-9611 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019611


101401-9611 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101401-9611 1014019611

Cross reference number

ZEXEL 101401-9611 1014019611


Zexel num
Bosch num
Firm num
Name
101401-9611 
 
  DPICO
INJECTION-PUMP ASSEMBLY
K-1 * 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   131424-5620
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   3.9 3.85 3.95
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   11.5+-0. 5
Pump speed r/min   1000 1000 1000
Each cylinder's injection qty mm3/st.   60 58.5 61.5
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
Each cylinder's injection qty mm3/st.   15 12.7 17.3
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.5)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   60 59 61
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.3
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   56 52 60
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.4
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   39.6 35.6 43.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   70 70 80
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1700
Advance angle deg.   5.5 5 6
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9611
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L56
----------

Speed control lever angle

Test data 101401-9611
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 101401-9611
N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee or less (non-injection rack position). (4)- (5)Rack position corresponding to ff (6)Free (at delivery)
----------
aa=40mm bb=1750r/min cc=(6.2)-0.5mm dd=300r/min ee=(8)mm ff=16mm
----------
a=25deg+-5deg b=20deg+-5deg c=35deg+-5deg

0000001501 ACTUATOR

Test data 101401-9611
(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=300r/min P1=66.7kPa(500mmHg) N2=500r/min R1=8.6mm P2=66.7kPa(500mmHg) R2=8.6mm
----------

Timing setting

Test data 101401-9611
(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=9deg
----------
a=(130deg)




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