Information injection-pump assembly
ZEXEL
101481-9070
1014819070
Rating:
Cross reference number
ZEXEL
101481-9070
1014819070
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
71.8
70.2
73.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
8.7+-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
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
71.8
70.8
72.8
Basic
*
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11)
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
79
75
83
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
Boost compensator adjustment
Pump speed
r/min
1100
1100
1100
Rack position
R1-2.3
Boost pressure
kPa
2.7
2.7
2.7
Boost pressure
mmHg
20
20
20
Boost compensator adjustment_02
Pump speed
r/min
1100
1100
1100
Rack position
R1-1.7
Boost pressure
kPa
20
18
22
Boost pressure
mmHg
150
135
165
Boost compensator adjustment_03
Pump speed
r/min
1100
1100
1100
Rack position
R1(11)
Boost pressure
kPa
66.7
66.7
66.7
Boost pressure
mmHg
500
500
500
Timer adjustment
Pump speed
r/min
1350--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1600
Advance angle
deg.
1.8
1.3
2.3
Timer adjustment_04
Pump speed
r/min
1800
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT: RAL
(3)Boost compensator stroke: BCL
----------
T1=71 RAL=14+0.2mm BCL=2.3+-0.1mm
----------
----------
T1=71 RAL=14+0.2mm BCL=2.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=60deg+-5deg b=41.5deg+-3deg
----------
----------
a=60deg+-5deg b=41.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=0deg+-5deg b=40deg+-5deg
----------
----------
a=0deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (position of gear's 'M' mark)
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
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.
Illustration 1 g06602736
Soft Joint
Illustration 2 g06602738
Hard Joint
Refer to Illustration 1 and 2 for updated design from soft joint to hard joint, to mitigate the joint relaxation and air leaks.The new and former part numbers are listed in Table 1.
Table 1
Required Parts
Qty New Part Number Part Name Former Part Number(1)
1 583-3212 Exhaust Bypass 259-1436
(1) The former part number listed is for reference only and may differ.Note: Service parts are not interchangeable between the former and new part number.