101401-7411 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014017411

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-7411 1014017411

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Cross reference number

ZEXEL 101401-7411 1014017411

Zexel num

Bosch num

Firm num

Name

101401-7411

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 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 134424-3920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.8 3.75 3.85

Rack position
Point A R=A

Beginning of injection position
Governor 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 13.1

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 97 95.4 98.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.7+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 14.5 13.2 15.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.1)

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 96.5 92.5 100.5

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_05

Adjusting point C

Rack position R2-0.45

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 86 82 90

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 127

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2-0.45

Boost pressure kPa 27.3 26 28.6

Boost pressure mmHg 205 195 215

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R2(R1-0. 6)

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Timer adjustment

Pump speed r/min 1185--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1135

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 4.8 4.3 5.3

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

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
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T1=N23 BCL=0.45+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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----------
a=42deg+-5deg b=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
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aa=64mm
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a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
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P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=410r/min Ra=9.75+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
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L=(5)mm

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=7deg
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a=(60deg) b=(85deg)

Information:

1. Disconnect air line (1) from the fuel ratio control.2. Remove wire seal (4) from the bolts.3. Remove bolts (3) that hold fuel ratio control (2).4. Remove the fuel ratio control by pulling down and out from the collar. The following steps are for the installation of the fuel ratio control.5. Put fuel ratio control (2) in position on the governor. Make sure the valve head of the fuel ratio control is connected in the groove of the collar.6. Install bolts (3) that hold the fuel ratio control to the governor. Connect air line (1) to the fuel ratio control.7. To make an adjustment to the fuel ratio control, see the topic "Governor Adjustment For The Air Fuel Ratio Control" in, Testing & Adjusting Manual SENR6471.8. Install wire seal (4) on the bolts with Tool (A).Disassemble & Assemble Fuel Ratio Control
Start By:a. remove fuel ratio control 1. Put Tool (A) in a vise so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in Tool (A). Remove bolts (3) and remove cover (26) and gasket (24).
There is spring force behind cover (7). Hold cover (7) in position, and slowly remove the bolts that hold it to release the spring force.
2. Remove bolts (6). Remove cover (7) from housing (10).3. Remove nut (5) and stop (4) from cover (7).4. Remove spring (8), washer (9) and diaphragm (21) from retainer (25). Remove retainer (25) from housing (10).5. Remove tube (1) from the end of extension (19). Remove nut (2) from extension (19) and remove the extension from retainer (25). Remove valve (16), spring (22) and O-ring seal (23) from the extension.6. Remove spring (20), retainer (18) and spring (17) from housing (10).7. Remove piston (12) and valve assembly (14) from the housing.8. Use Tool (B) and remove snap ring (13) and washer (15) from the valve assembly. Remove piston (12) from the valve assembly.9. Remove seal (11) from piston (12).10. If necessary, remove the stem portion from valve assembly (14).11. Clean and inspect all parts. Make a replacement of all parts that are worn and damaged. The following steps are for the assembly of the fuel ratio control.12. If removed during disassembly, assemble the stem portion of valve assembly (14) on the valve using 9S3265 Retaining Compound.13. Lubricate seal (11) lightly with the lubricant being sealed. Put seal (11) on piston (12) and put piston (12) on valve assembly (14).14. Put washer (15) in position on the valve assembly and use Tool (B) to install snap ring (13) on the valve assembly.15. Place housing (10) on Tool (A), and put Tool (C) into the bore of the housing. Lubricate Tool (C) with clean engine oil.16. Push piston (12) into position with a smooth swift motion. Remove Tool (C) from the housing. Place spring (17), retainer (18) and spring (20) in housing (10).17. Put O-ring seal (23) on extension (19). Put spring (22) and valve (16) in position on the