101401-1840 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014011840

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-1840 1014011840

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Cross reference number

ZEXEL 101401-1840 1014011840

Zexel num

Bosch num

Firm num

Name

101401-1840

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 131424-4620

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.5 3.45 3.55

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 10.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 87 86 88

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 475 475 475

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 55 55 60

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 0

Advance angle deg. 2.5 2 3

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2 3

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min 750+-25

Advance angle deg. 0 0 0

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=6
----------

Speed control lever angle

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

----------
a=3deg+-5deg b=18deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Use the hole at R = aa
----------
aa=30mm
----------
a=53deg+-5deg b=26.5deg+-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=12deg
----------
a=(130deg)

Information:

4.236 Engines(1) First (top) compression ring: Width of compression ring ... 2.362 to 2.375 mm (.0930 to .0935 in)Clearance between ends of ring installed in cylinder liner that has no wear ... 0.25 to 0.56 mm (.010 to .022 in)(2) Second compression ring: Width of compression ring ... 2.362 to 2.375 mm (.0930 to .0935 in)Clearance between ends of each ring installed in cylinder liner that has no wear ... 0.20 to 0.56 mm (.008 to .022 in)(3) Oil ring: Width of oil ring ... 4.724 to 4.737 mm (.1860 to .1865 in)Clearance between ends of each ring installed in cylinder liner that has no wear ... 0.25 to 0.53 mm (.010 to .021 in)(4) Width of groove for first compression ring ... 2.46 to 2.49 mm (.097 to .098 in) Ring clearance in the groove ... 0.089 to 0.127 mm (.0035 to .0050 in)(5) Width of groove for second compression ring ... 2.44 to 2.46 mm (.096 to .097 in) Ring clearance in the groove ... 0.064 to 0.102 mm (.0025 to .0040 in)(6) Width of groove for oil ring ... 4.788 to 4.806 mm (.1885 to .1892 in) Ring clearance in the groove ... 0.051 to 0.081 mm (.0020 to .0032 in)(7) Bore in piston for pin ... 34.9212 to 34.9263 mm (1.37485 to 1.37505 in) Diameter of piston pin (new) ... 34.920 to 34.93 mm (1.3748 to 1.375 in)Piston height above cylinder block (not shown) ... 0.36 to 0.58 mm (.014 to .023 in)C4.236 Engines
C4.236 Engines(1) First (top) compression ring: Width of compression ring ... wedge shapedClearance between ends of ring installed in cylinder liner that has no wear ... 0.25 to 0.61 mm (.010 to .024 in)(2) Second compression ring: Width of compression ring ... 2.362 to 2.375 mm (.0930 to .0935 in)Clearance between ends of each ring installed in cylinder liner that has no wear ... 0.25 to 0.69 mm (.010 to .027 in)(3) Oil ring: Width of oil ring ... 4.724 to 4.763 mm (.1860 to .1875 in)Clearance between ends of each ring installed in cylinder liner that has no wear ... 0.25 to 0.79 mm (.010 to .031 in)(4) Width of groove for first compression ring ... tapered(5) Width of groove for second compression ring ... 2.426 to 2.446 mm (.0955 to .0963 in) Ring clearance in the groove ... 0.051 to 0.084 mm (.0020 to .0033 in)(6) Width of groove for oil ring ... 4.788 to 4.808 mm (.1885 to .1893 in) Ring clearance in the groove ... 0.025 to 0.084 mm (.0010 to .0033 in)(7) Bore in piston for pin ... 38.100 to 38.1005 mm (1.5000 to 1.50002 in) Diameter of piston pin (new) ... 38.095 to 38.100 mm (1.4998 to 1.5000 in)Piston height above cylinder block (not shown) ... 0.36 to 0.58 mm (.014 to .023 in)