101491-9275 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919275

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101491-9275 1014919275

Service parts 101491-9275 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9230

3. GOVERNOR 105921-1425

4. SUPPLY PUMP 105220-5252

5. AUTOM. ADVANCE MECHANIS 105670-0210

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4252

11. Nozzle and Holder SL50 13 H50A

12. Open Pre:MPa(Kqf/cm2) 16.7{170}

13. NOZZLE-HOLDER 105048-3121

14. NOZZLE 105017-0211

15. NOZZLE SET

Include in #1:

101491-9275 as INJECTION-PUMP ASSEMBLY

101605-3081 as _

Cross reference number

ZEXEL 101491-9275 1014919275

Zexel num

Bosch num

Firm num

Name

101491-9275

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 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 12.77+-0 .02

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.2 72.7 73.7

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 340 340 340

Average injection quantity mm3/st. 10 8 12

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 12.77+-0 .5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.2 72.7 73.7

Basic *

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_04

Adjusting point B

Rack position 12.91+-0 .5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 83.7 81.7 85.7

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_05

Adjusting point C

Rack position 11.97+-0 .5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 49.3 47.3 51.3

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_06

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 600 600 600

Rack position 10.49+-0 .05

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 11.69+-0 .02

Boost pressure kPa 12 9.3 14.7

Boost pressure mmHg 90 70 110

Timer adjustment

Pump speed r/min 1500+-25

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1750

Advance angle deg. 3 2.7 3.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: R1, speed N1 (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=C07 R1=+-0.02mm N1=+-3r/min BCL=1.2+-0.1mm
----------

Speed control lever angle

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

----------
a=20deg+-5deg b=43deg+-3deg

Stop lever angle

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=340r/min
----------
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.
----------
N1=1.5
----------

0000001601 GOV RACK POSITION CONFIRM

Confirm the governor adjustment rack position. (N): Speed of the pump (R) Rack position (mm) Standard point A (B) Confirmation Remarks C
----------

----------
Na=1000r/min Nb=625r/min Nc=1700r/min Nd=1500r/min Ne=1250r/min Nf=400r/min Ra=12.77+-0.02mm Rb=11.69+-0.02mm Rc=12.84+-0.05mm Rd=13.04+-0.05mm Re=13.23+-0.05mm Rf=12.15+-0.05mm