101481-9040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014819040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101481-9040 1014819040

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Cross reference number

ZEXEL 101481-9040 1014819040

Zexel num

Bosch num

Firm num

Name

101481-9040

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 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 2.8 2.75 2.85

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 10.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.6 60.6 62.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 84 84

Boost pressure mmHg 630 630

Injection quantity adjustment_02

Adjusting point B

Rack position 9.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 28.3 24.3 32.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point -

Rack position 8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8 12

Max. variation between cylinders % 0 -15 15

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.

Injection quantity adjustment_04

Adjusting point D

Rack position 13.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 81 71 91

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 9.5

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10.5

Boost pressure kPa 70.6 63.9 77.3

Boost pressure mmHg 530 480 580

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 1.2 0.7 1.7

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT
----------
K=11
----------

Speed control lever angle

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

----------
a=(17deg)+-5deg b=(27deg)+-5deg

Stop lever angle

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

----------
a=16.5deg+-5deg b=50deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=5.5mm
----------
a1=A a2=B a3=- a4=- r1=1100r/min r2=1000r/min r3=- r4=- Q1=68.8+-1mm3/st Q2=61.6+-1mm3/st Q3=- Q4=- c1=+-2.5% c2=+-2.5% c3=- c4=- a5=32 a6=31 a7=30 a8=29 a9=28 a10=27 a11=26 a12=25 a13=- a14=- a15=- r5=1600r/min r6=1550r/min r7=1500r/min r8=1450r/min r9=1400r/min r10=1350r/min r11=1300r/min r12=1250r/min r13=- r14=- r15=- R5=1720+-40r/min R6=1665+-38r/min R7=1610+-37r/min R8=1555+-36r/min R9=1505+-35r/min R10=1450+-33r/min R11=1395+-32r/min R12=1340+-31r/min R13=- R14=- R15=-

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'B') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(60deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former DEF filter part numbers are listed in Table 1.
Table 1
Required Parts
Qty New Part Number Part Name Former Part Numbers(1)
1 584-8135 Diesel Exhaust Fluid Filter Gp 453-1604
1 584-8136 Diesel Exhaust Fluid Filter Gp 453-1605
1 584-8137 Diesel Exhaust Fluid Filter Gp 453-1606
(1) The former part number listed is for reference only and may differ.