101401-1801 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014011801

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-1801 1014011801

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Service parts 101401-1801 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9420

3. GOVERNOR 105921-9830

4. SUPPLY PUMP 105220-7120

5. AUTOM. ADVANCE MECHANIS 105676-1000

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5761

11. Nozzle and Holder ME016992

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3501

14. NOZZLE 105017-2240

15. NOZZLE SET

Include in #1:

101401-1801 as INJECTION-PUMP ASSEMBLY

108822-3105 as _

Cross reference number

ZEXEL 101401-1801 1014011801

Zexel num

Bosch num

Firm num

Name

101401-1801

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 131424-8820

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 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 -

Rack position 11.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 71.5 69.9 73.1

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 H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 71.5 70.5 72.5

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.4

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 87 83 91

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.7

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53 49 57

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.7

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 17.2 13.2 21.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-0.7

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-0. 5)

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 2.5 2 3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=L43 BCL=0.7+-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=40.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=40mm
----------
a=33deg+-5deg b=40deg+-5deg

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=10deg
----------
a=(130deg)

Information:

6N9294 Alternator Group, 3T6352 Alternator 24V 35A (Delco-Remy Number 1117647)
Load the battery with a carbon pile (6V4930 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (hot) ... 35A(1) Torque for the ground terminal nut ... 2.3 0.6 N m (21 5 lb in)(2) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(3) Torque for the output terminal nut ... 7.1 0.9 N m (64 8 lb in)3T6354 Regulator (Delco-Remy Number 1116405) Inside Alternator
Voltage setting ... No adjustmentPermissible voltage range ... 26 to 30VDelco-Remy (25SI)
5S9088 Alternator Group, 3T1888 Alternator 24V 50A (Delco-Remy Number 1117248)
Load the battery with a carbon pile (6V4930 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output (hot) ... 50A(1) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(2) Torque for the output terminal nut ... 13.5 1.3 N m (10 1 lb ft)7N129 Regulator (Delco-Remy Number 1892824) Inside Alternator
Voltage setting range ... 27.5 1.0VAdjust voltage setting to ... 28V There are two types of adjustment: One type of adjustment is made by removing a pipe plug and turning the adjusting screw one or two notches in a clockwise direction to increase the voltage setting or one or two notches in a counterclockwise direction to decrease the voltage setting. The second type of adjustment is similar except, remove the end cover to expose the potentiometer for adjustment.Then increase speed to get a maximum output of ... 50ABosch
6N9294 Alternator Group, 7N9720 Alternator 24V 35A (Bosch Number 0-122-469-001)
Load the battery with a carbon pile (6V4930 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (hot) ... 37ATorque for the ground terminal nut ... 2.1 to 2.8 N m (19 to 25 lb in)(1) Torque for the pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for the output terminal nut ... 13.5 1.3 N m (10 1 lb ft)9G7567 Regulator (Bosch Number 1-197-011-000) Under Alternator Cover. For