101481-9100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014819100

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101481-9100 1014819100

Cross reference number

ZEXEL 101481-9100 1014819100

Zexel num

Bosch num

Firm num

Name

101481-9100

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 132424-0620

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

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT
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K=11
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(17deg)+-5deg b=(27deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=16.5deg+-5deg b=50deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

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
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L=5.5mm
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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

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