101402-9861 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029861

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9861 1014029861

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Cross reference number

ZEXEL 101402-9861 1014029861

Zexel num

Bosch num

Firm num

Name

101402-9861

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 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 3.6 3.55 3.65

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 10.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 45 44 46

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 11.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 55 65

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 (6)Rack difference between N = N1 and N = N2
----------
K=8 N1=1100r/min N2=650r/min
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Speed control lever angle

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

----------
a=6deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal stop
----------

----------
a=58deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Appendix
Configuration Information
Table 7
Over-Temp
Inlet Over-Temperature Alarm
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Active Output During Alarm Output 1
Output function ON only during alarm
Assert Alarm Above
650 °C (1202 °F)
Hysteresis
20 °C (68 °F)
Upon Over Temperature extend alarm for 60 seconds
Table 8
Over-Pres
Over-Pressure Warning
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Active Output During Alarm Output 1
Output Function ON only during alarm
Assert Alarm when the measured pressure exceeds 7" of Hg for 5% of the time during a 60 min measurement interval
Over-Pressure Alarm
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Active Output During Alarm Output 2
Output Function Latched ON upon alarm
Assert alarm when the measured pressure exceeds 8" of Hg for 5% of the time during a 60 min measurement interval
Table 9
TC-Fail (1)
Open Thermocouple Detect
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Output During Alarm Output 1
Output Function Latched ON upon alarm
Assert alarm if measured temperature is above
1000 °C (1832 °F)
Shorted Thermocouple Detect
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Output During Alarm Output 1
Output Function Latched ON upon alarm
Assert alarm if pressure is greater than 1" of Hg for 10 min and measured temperature does not exceed
120 °C (248 °F)
( 1 ) Output selection applies to both open and shorted alarms
Table 10
Pressure Sensor Fail
No Change Alarm
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Active Outputs During Alarm Output 1
Output Function Latched ON upon Alarm
Assert alarm if exhaust temperature is above
250 °C (482 °F) for 10 min and the pressure doesn't change by at least 0.25" of Hg
Negative Pressure Alarm
Condition Expected Value
Enable Alarm Yes
Log Alarm Transitions Yes
Active Output During Alarm Output 1
Output Function Latched ON during alarm
Assert Alarm if temperature is above
200 °C (392 °F) for 10 min and the pressure is less than −1" of