101401-9591 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019591


101401-9591 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101401-9591 1014019591

Cross reference number

ZEXEL 101401-9591 1014019591


Zexel num
Bosch num
Firm num
Name
101401-9591 
 
  DPICO
INJECTION-PUMP ASSEMBLY
K-1 * Q

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   131424-5620
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   1-3-4-2
Pre-stroke mm   3.9 3.85 3.95
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   11.5+-0. 5
Pump speed r/min   1000 1000 1000
Each cylinder's injection qty mm3/st.   60 58.5 61.5
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
Each cylinder's injection qty mm3/st.   15 12.7 17.3
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.5)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   60 59 61
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.3
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   56 52 60
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.4
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   39.6 35.6 43.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   70 70 80
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1700
Advance angle deg.   5.5 5 6
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9591
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L56
----------

Speed control lever angle

Test data 101401-9591
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=40mm
----------
a=26deg+-5deg b=(42deg)+-3deg

Stop lever angle

Test data 101401-9591
N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. Confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed dd. (Rack position = ee or less) (4)Non-injection rack position (5)Rack position corresponding to ff (6)Free (at delivery)
----------
aa=40mm bb=1750r/min cc=(6.2)-0.5mm dd=300r/min ee=(8)mm ff=16mm
----------
a=25deg+-5deg b=20deg+-5deg c=35deg+-5deg

Timing setting

Test data 101401-9591
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=9deg
----------
a=(130deg)




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