Information injection-pump assembly
ZEXEL
101401-1073
1014011073
Rating:
Cross reference number
ZEXEL
101401-1073
1014011073
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
131424-6220
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
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
3.6
3.55
3.65
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
10.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
53.1
52.1
54.1
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
-
Rack position
9.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
10
8.7
11.3
Max. variation between cylinders
%
0
-10
10
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(10.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
53.1
52.1
54.1
Basic
*
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.6
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
72.7
68.7
76.7
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
40.4
36.4
44.4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2+0.7
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
39.4
35.4
43.4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
67
67
72
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-0.4
Boost pressure
kPa
22.7
22.7
22.7
Boost pressure
mmHg
170
170
170
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R1-0.2
Boost pressure
kPa
27.3
26
28.6
Boost pressure
mmHg
205
195
215
Boost compensator adjustment_03
Pump speed
r/min
700
700
700
Rack position
R1(10.6)
Boost pressure
kPa
36
29.3
36
Boost pressure
mmHg
270
220
270
Timer adjustment
Pump speed
r/min
1450
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_02
Pump speed
r/min
1700
Advance angle
deg.
3.5
3
4
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=C64 BCL=0.4+-0.1mm
----------
----------
T1=C64 BCL=0.4+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=42deg+-3deg
----------
aa=40mm
----------
a=26deg+-5deg b=42deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop
(1)Free (at shipping)
(2)Use the hole at R = aa
(3)Rack position corresponding to bb
(4)Set the stopper bolt so that speed = cc and rack position = dd. Confirm non-injection. After setting the stopper bolt, confirm non-injection at speed = ee (rack position = ff or less).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=950+-5r/min Ra=8mm
----------
----------
N1=950+-5r/min Ra=8mm
----------
0000001601 ACTUATOR
(a) Screw
(B) Nut
(c) set bolt
(d) control lever
1. Actuator adjustment procedure
(1)Position the control lever (d) in the idling position.
(2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1 mm.
(3)Loosen the nut (b) and fully tighten the screw (a).
(4)Apply negative pressure P1 kPa (mmHg) to the actuator.
(5)Read the rack position when the pump speed is N1 r/min.
(6)Loosen screw (a) and fix the nut (b) when the pump speed is N2 r/min and the rack position is R1 mm.
(7)Confirm that lever (d) returns to the idling position at actuator negative pressure 0.
(8)Repeat procedures (4) to (7) several times and confirm that the lever (d) moves smoothly.
----------
L1=(2) mm R1=9.1 mm P1=66.7 kPa(500 mmHg) N1=500 r/min N2=500 r/min
----------
----------
L1=(2) mm R1=9.1 mm P1=66.7 kPa(500 mmHg) N1=500 r/min N2=500 r/min
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(130deg)
----------
aa=11deg
----------
a=(130deg)
Information:
No-load testAlternator
If a problem occurs in the charge system, check the following conditions to locate the cause of the problem. Only when inspection cannot be conducted on the alternator in the installed condition, dismount the alternator for inspection and repair. On Vehicle Inspection
(1) Cautions for handlingHandle the alternator carefully, as incorrect handling can result in alternator damage or malfunctions.(a) Do not connect the battery cables in reverse. Note the negative (-) cable is a grounding wire.(b) Do not use a high-voltage tester such as a megger.(c) When charging the battery, disconnect the cables from the battery terminals.(d) Do not disconnect the lead wire from terminal B of the alternator while the engine is operating.(e) Do not ground terminal B of the alternator since it is constantly applied with battery voltage.(f) Do not short-circuit or ground terminal L. (unit with integrated IC regulator)(g) When using a steam cleaner, do not allow steam to directly contact the alternator.(2) Inspection of adjustment voltage (unit with integrated IC regulator)(a) Disconnect the cable from the positive (+) terminal of the battery, and connect an ammeter between the terminal and cable.(b) Connect a voltmeter between terminal L and ground.(c) Make sure that the voltmeter indicates "0" when the starter switch is turned off. Make sure that the voltmeter indicates a voltage level significantly lower than the battery voltage when the starter switch is turned on (without starting the engine).(d) Short-circuit the terminal of the ammeter, and start the engine.(e) Read the indication (adjustment voltage) on the voltmeter with the ammeter indicating 5A or lower, the engine operating at 1500 to 2500 min-1, and the lamp switches turned off.
Inspection of adjustment voltage (3) Inspection of output (unit with integrated IC regulator)(a) Disconnect the grounding cable from the battery.(b) Disconnect the wire from terminal B of the alternator, and connect an ammeter, then connect a voltmeter between B and ground.(c) Reconnect the grounding cable to the battery.(d) Start the engine.(e) Immediately after the engine starts, turn on all load devices such as lamps.(f) Increase the engine speed, and read the maximum current at the specified alternator rotation speed when the voltmeter indicates 27.0 V. If the measured value conforms to the standard value, the alternator is normal.
Wiring for output test (unit with integrated IC regulator) Disassembly of Alternator
(1) Separation of front bracket from stator coreInsert the tip of a slotted screwdriver into the gap between the stator core and front bracket, and pry open.
Do not insert the screwdriver too far into the assembly to prevent damaging the stator core.
Separation of front bracket from stator core(2) Removal of pulley(a) After wrapping the rotor with a cloth for protection and holding it with a vice, unscrew the pulley nut, then remove the pulley and spacer.(b) Remove the rotor from the front bracket.
Removal of pulley(3) Removal of stator core and rectifier(a) Disconnect the lead wires between the stator core and the rectifier at the soldered sections, and remove the stator core.
Melt the soldered sections as quickly as possible. Prolonged