101402-4980 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014024980

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-4980 1014024980

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Cross reference number

ZEXEL 101402-4980 1014024980

Zexel num

Bosch num

Firm num

Name

101402-4980

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 A

Rack position 9

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 88 86.9 89.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8 6.6 9.4

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 165 160 170

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=5
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=1deg+-5deg b=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(100deg)

Information:

POSITIONING PIN BEARING
MARKS FOR TIGHTENING CONNECTING ROD BOLTS(1) Bore in connecting rod for piston pin bearing ... 2.1825 .0005 in.(55.436 0.013 mm) Tight fit between connecting rod eye and piston pin bearing ... .002 to .004 in.(0.05 to 0.10 mm) Connecting rod must be heated for installation of piston pin bearing. Do not use a torch.Heat connecting rod to temperature of ... 350 to 500° F (177 to 260° C) Piston pin bearing junction must be assembled within either area "A" (90 10° from the centerline through the connecting rod bores) as shown.(2) Bore in connecting rod for bearing with nuts tight to specifications (6) ... 4.0748 .0005 in.(103.500 0.013 mm)(3) Distance between center of bearings ... 10.300 .002 in.(261.62 0.05 mm)(4) Bore in bearing for piston pin (new) ... 2.0012 .0003 in.(50.830 0.008 mm) Diameter of piston pin (new) ... 1.9998 .0002 in.(50.795 0.005