101495-3500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953500


101495-3500 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101495-3500 1014953500

Cross reference number

ZEXEL 101495-3500 1014953500


Zexel num
Bosch num
Firm num
Name
101495-3500 
 
   
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
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   1-2-4-3
Pre-stroke mm   3.2 3.15 3.25
Rack position
After adjusting injection quantity.
  R=A
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cal 1-3
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   A
Rack position   10.8
Pump speed r/min   925 925 925
Average injection quantity mm3/st.   63 62 64
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   8.3+-0.5
Pump speed r/min   575 575 575
Average injection quantity mm3/st.   8 7 9
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 

Test data Ex:

Governor adjustment

Test data 101495-3500
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Deliver without the torque control spring operating. (4)RACK CAP: R1 (5)Set idle sub-spring (6)Main spring setting
----------
K=6 R1=(17.5)mm
----------

Speed control lever angle

Test data 101495-3500
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=7deg+-5deg b=13deg+-5deg

Stop lever angle

Test data 101495-3500
N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)No return spring
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)

0000001501 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------

----------

Timing setting

Test data 101495-3500
(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)After adjusting the injection quantity, adjust at rack position aa. (5)-
----------
aa=10.8mm
----------
a=58deg+-3deg b=2deg+-30min




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