101495-3221 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953221

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101495-3221 1014953221

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Service parts 101495-3221 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8900

3. GOVERNOR 105400-7511

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4710

11. Nozzle and Holder 6202-13-3300

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE

105017-0630

15. NOZZLE SET

Include in #1:

101495-3180 as _

101495-3221 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101495-3221 1014953221

Zexel num

Bosch num

Firm num

Name

101495-3221

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 131424-7420

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 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 1-2-4-3

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 70.2 69.2 71.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 10.5 9.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Rack difference between N = N1 and N = N2
----------
K=12 RAL=12.5+0.2mm N1=1000r/min N2=750r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=8deg+-5deg b=32deg+-3deg c=29deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=37deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)-
----------

----------
a=58deg+-3deg b=2deg+-30min

Information:

API Degrees - Temperature Correction Chart for Diesel Fuel
Record the corrected API gravity from this chart.Table of Horsepower Correction Factors
Table 2
Corrected API
Gravity at 60° F Precombustion
Chamber Engines Direct Injection Engines (Use the correct full load RPM)
1800 2000 2200 2400 2600 2800 3000 3200
32.0
32.5
33.0
33.5
34.0 .984
.987
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995
34.5
35.0
35.5
36.0
36.5 .997
1.000
1.003
1.005
1.008 .998
1.000
1.003
1.007
1.013 .998
1.000
1.003
1.007
1.010 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012
37.0
37.5
38.0
38.5
39.0 1.011
1.014
1.017
1.020
1.023 1.014
1.018
1.022
1.025
1.029 1.014
1.018
1.022
1.026
1.030 1.014
1.018
1.022
1.026
1.030 1.015
1.019
1.022
1.026
1.030 1.015
1.019
1.023
1.027
1.031 1.016
1.020
1.024
1.028
1.032 1.016
1.020
1.024
1.028
1.033 1.016
1.021
1.025
1.029
1.034
39.5
40.0
40.5
41.0
41.5 1.027
1.030
1.034
1.038
1.043 1.034
1.038
1.043
1.048
1.053 1.034
1.038
1.043
1.048
1.054 1.034
1.039
1.044
1.049
1.055 1.035
1.040
1.045
1.050
1.056 1.036
1.040
1.045
1.051
1.056 1.036
1.041
1.046
1.051
1.057 1.037
1.042
1.047
1.053
1.059 1.039
1.045
1.047
1.057
1.064
42.0
42.5
43.0
43.5
44.0 1.047
1.053
1.060
1.067
1.076 1.059
1.066
1.073
1.082
1.095 1.060
1.067
1.074
1.084
1.096 1.061
1.068
1.076
1.085
1.098 1.062
1.069
1.077
1.086
1.099 1.063
1.070
1.078
1.087
1.100 1.064
1.071
1.079
1.088
1.102 1.066
1.072
1.081
1.091
1.105 1.072
1.080
1.089
1.099
1.115 Use the above chart to find the horsepower correction factor.Calculating the Corrected Horsepower
Determine the rated full load horsepower from the Rack Setting Information Book.
Divide the rated horsepower by the horsepower correction factor for fuel density; the result is the corrected horsepower.Example:1674 - Truck Engine Serial No. 94B2551Rated Horsepower: 270 HorsepowerCalculations:
Table 3
1. Measured API gravity: 40.4' API at 50' (round to 40' API)
2. Corrected API gravity (see chart): 41' API at 60'F
3. Hpr correction factor (see chart): 1.038
4. Corrected Hp = Rated Hpr = 270 = 260 Hp
Correction Factor 1.038 (or 3.75% hp loss) Correcting for Fuel Density When Testing Engines on a Dynamometer
When engines are tested on a dynamometer which measures actual flywheel or drive train output, the observed horsepower is dependent on the fuel used. If the fuel being used is not 35° API at 60°F, then any dynamometer readings must be corrected to determine the output if 35° API fuel had been used. The same horsepower correction factor is used, but the formula is different:Corrected Horsepower = Observed Horsepower x Horsepower Correction FactorExample:1674 Truck Engine, Serial No. 9482551Rated (full load Horsepower: 270 Horsepower)Observed (dynamometer) Horsepower: 260 HorsepowerCalculations:
Measured API gravity: 39.6° API at 50°F (round to 40° API)
Corrected API Gravity (see chart): 41° API at 60°F
Horsepower Correction Factor (see chart): 1.038
Corrected Horsepower = Observed Horsepower x Horsepower Correction Factor 260 horsepower x 1.038 = 270 horsepower(Although the dynamometer indicated low horsepower, if the proper fuel had been used, the engine would be operating at rated output. The factory tolerance on rated engine output is 3%.)REFERENCE: For more information on dynamometer testing diesel engines, see Special Instruction Form GEG01024 .Diesel Fuel API Gravity to IbsJU.S. gallon or kg/liter Conversion Chart
The following chart may be used to convert the fuel API gravity to Ibs./U.S. gallon or kg/liter. These weights are for reference and are to be used when evaluating engine performance. Measurement of fuel flow rates can be converted

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