101481-9040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014819040


101481-9040 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101481-9040 1014819040

Cross reference number

ZEXEL 101481-9040 1014819040


Zexel num
Bosch num
Firm num
Name
101481-9040 
 
   
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 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   2.8 2.75 2.85
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   A
Rack position   10.5
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   61.6 60.6 62.6
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   84 84
Boost pressure mmHg   630 630
Injection quantity adjustment_02
Adjusting point   B
Rack position   9.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   28.3 24.3 32.3
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_03
Adjusting point   -
Rack position   8+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   10 8 12
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_04
Adjusting point   D
Rack position   13.3+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   81 71 91
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   9.5
Boost pressure kPa   12 10.7 13.3
Boost pressure mmHg   90 80 100
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   10.5
Boost pressure kPa   70.6 63.9 77.3
Boost pressure mmHg   530 480 580
Timer adjustment
Pump speed r/min   800--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   700
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1200
Advance angle deg.   1.2 0.7 1.7
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101481-9040
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT
----------
K=11
----------

Speed control lever angle

Test data 101481-9040
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(17deg)+-5deg b=(27deg)+-5deg

Stop lever angle

Test data 101481-9040
N:Pump normal S:Stop the pump.
----------

----------
a=16.5deg+-5deg b=50deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Test data 101481-9040
Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=5.5mm
----------
a1=A a2=B a3=- a4=- r1=1100r/min r2=1000r/min r3=- r4=- Q1=68.8+-1mm3/st Q2=61.6+-1mm3/st Q3=- Q4=- c1=+-2.5% c2=+-2.5% c3=- c4=- a5=32 a6=31 a7=30 a8=29 a9=28 a10=27 a11=26 a12=25 a13=- a14=- a15=- r5=1600r/min r6=1550r/min r7=1500r/min r8=1450r/min r9=1400r/min r10=1350r/min r11=1300r/min r12=1250r/min r13=- r14=- r15=- R5=1720+-40r/min R6=1665+-38r/min R7=1610+-37r/min R8=1555+-36r/min R9=1505+-35r/min R10=1450+-33r/min R11=1395+-32r/min R12=1340+-31r/min R13=- R14=- R15=-

Timing setting

Test data 101481-9040
(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'B') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(60deg)




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