101605-9450 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016059450

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101605-9450 1016059450

Cross reference number

ZEXEL 101605-9450 1016059450

Zexel num

Bosch num

Firm num

Name

101605-9450

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 131424-1520

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 1-4-2-6- 3-5

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 89.5 87.5 91.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point C

Rack position R1(9.1)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 55 54 56

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 9.5 7.7 11.3

Max. variation between cylinders % 0 -10 10

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.

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1(9.1)

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position (10.1)

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting (7)Rack difference between N = N1 and N = N2
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K=8 L1=11.7+-0.1mm BCL=(1)mm N1=1150r/min N2=700r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(11deg)+-5deg b=(22deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=26.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0.
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aa=11.7+-0.1mm
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a=(15deg) b=(25deg)

Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(60deg)