101405-9090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014059090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101405-9090 1014059090

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Cross reference number

ZEXEL 101405-9090 1014059090

Zexel num

Bosch num

Firm num

Name

101405-9090

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
Inside diameter - outside diameter - length (mm) mm 6-2-600

Overflow valve 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 9.7

Pump speed r/min 975 975 975

Average injection quantity mm3/st. 110.5 109.5 111.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point D

Rack position 6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 11.5 10.2 12.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point E

Rack position 10++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 105 105 110

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
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K=10
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Base lever only
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a=31deg+-3deg b=1deg+-5deg c=19deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Use the hole at R = aa (3)Speed = bb, rack position = cc (sealed at delivery)
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aa=23mm bb=0r/min cc=1-0.5mm
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a=0deg+-5deg b=(55deg)

Timing setting

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

----------
a=(50deg)

Information:

Torque For Standard Bolts, Nuts And Taperlock Studs
The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.
Torques For Bolts And Nuts With Standard Threads
Torques For Taperlock Studs
Use these standard torque values for all fasteners unless otherwise specified in this publication or in the Service Manual.Torque For Metric Fasteners
Be very careful never to mix metric with customary (standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury. Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.The material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). The following chart gives general torques for bolts and nuts with Grade 8.8.
Torque For Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of those clamps on new hose and for reassembly or tightening of hose clamps on existing hose.
Constant Torque Hose Clamps
A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp.Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Installation
Each installation application can be different depending on the type of hose, fitting material and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of the new, constant torque hose clamps. Constant torque hose clamps should be installed as follows: To allow for maximum expansion, install clamps at 50 lb in (5.7 N m).To allow for equal expansion and contraction, install clamps at 90 lb in (10.2 N m).To allow for maximum contraction, install clamps at 125 lb in (14.1 N m).