101491-9271 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919271

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101491-9271 1014919271

Cross reference number

ZEXEL 101491-9271 1014919271

Zexel num

Bosch num

Firm num

Name

101491-9271
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 12.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 74 73.5 74.5

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(12.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 74 73.5 74.5

Basic *

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+0.6)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 87.6 83.6 91.6

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. 75 70 85

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 1400 1400 1400

Rack position R1-0.35

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 1400 1400 1400

Rack position R1+0.85

Boost pressure kPa 11.3 11.3 11.3

Boost pressure mmHg 85 85 85

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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
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T1=B80 T1=1.2+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=20deg+-5deg b=(38deg)+-3deg

Stop lever angle

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

0000001501 LEVER

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.
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N1=1.5
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