101491-9270 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919270


101491-9270 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101491-9270 1014919270

Cross reference number

ZEXEL 101491-9270 1014919270


Zexel num
Bosch num
Firm num
Name
101491-9270 
101491-9276 
 
  MAZDA
INJECTION-PUMP ASSEMBLY
P630K *

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   131424-3420
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   3.2 3.15 3.25
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   12.1
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   69.8 68.3 71.3
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   300 300 300
Average injection quantity mm3/st.   8 6 10
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.1)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   69.8 68.8 70.8
Basic   *
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_04
Adjusting point   B
Rack position   (R1-0.15 )
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   77.1 73.1 81.1
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   84.5 74.5 94.5
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   700 700 700
Rack position   R2-1.1
Boost pressure kPa   2 2 4.7
Boost pressure mmHg   15 15 35
Boost compensator adjustment_02
Pump speed r/min   700 700 700
Rack position   R2(R1-0. 3)
Boost pressure kPa   6.7 6.7 6.7
Boost pressure mmHg   50 50 50
Timer adjustment
Pump speed r/min   850+-25
Advance angle deg.   1 0.7 1.3
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   925
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1400+-25
Advance angle deg.   0 0 0
Timer adjustment_04
Pump speed r/min   1700+-25
Advance angle deg.   3.5 3.2 3.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101491-9270
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B61 BCL=1.1+-0.1mm
----------

Speed control lever angle

Test data 101491-9270
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=20deg+-5deg b=45deg+-3deg

Stop lever angle

Test data 101491-9270
N:Pump normal S:Stop the pump. (1)Normal (2)Stop (3)Stopper bolt setting (4)Set the speed to aa using the idle lever and then confirm non-injection.
----------
aa=300r/min
----------
a=(15deg)+-5deg b=(13.5deg) c=23deg+-5deg d=40deg+-5deg

0000001501 LEVER

Test data 101491-9270
f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever Stop lever's normal position setting method 1. (1) Push in the set bolt (A) until the rack starts to move. (2)Return the bolt N1 turns from that position and set. 2. Rack with limiter (1)Return the bolt N1 turns from the rack limit position and set.
----------
N1=1.5
----------

Timing setting

Test data 101491-9270
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(130deg)




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