101401-9014 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019014

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9014 1014019014

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Service parts 101401-9014 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9640

3. GOVERNOR 105921-3781

4. SUPPLY PUMP 105210-3300

5. AUTOM. ADVANCE MECHANIS 105671-0091

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4871

11. Nozzle and Holder TF01 13 H50

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3450

14. NOZZLE 105017-0861

15. NOZZLE SET

Include in #1:

101401-9014 as INJECTION-PUMP ASSEMBLY

106671-8793 as _

106671-8794

Cross reference number

ZEXEL 101401-9014 1014019014

Zexel num

Bosch num

Firm num

Name

101401-9014

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 131424-3420

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 1-3-4-2

Pre-stroke mm 3.3 3.25 3.35

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 12.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 64.6 64.1 65.1

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. 9 7 11

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(12.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 64.6 64.1 65.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1625 1625 1625

Average injection quantity mm3/st. 79.3 75.3 83.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 47.4 43.4 51.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 160

Fixing the lever *

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min 1625

Advance angle deg. 3.8 3.5 4.1

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.
----------
T1=E03
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=20deg+-5deg b=(41deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(29.5deg)+-5deg

0000001501 LEVER

CL:Center line of camshaft ST:Stop adjuster screw f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever 1. Stop lever adjustment outline (1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position. (2)Set the speed lever in the full speed position. (3)At pump speed Na, position the rack at non-injection position Ra. (4)Set the stop adjusting screw to fix the speed lever in the idling position. (5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=4.7+-0.3mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(130deg)

Information:

1. Disconnect air line (1) at fitting. Remove two bolts (2). Pull up and toward the front of the engine to remove the bolt of the fuel ratio from the groove (slot) in the collar for the governor. Remove fuel ratio control (3). Remove gasket from fuel ratio control.2. Install a new gasket on fuel ratio control. Install fuel ratio control (3). Make sure bolt engages with stop collar in governor control.3. Install two bolts (2). Connect air line (1) at fitting.4. Make sure the fuel ratio control is in correct adjustment. See Systems Operation Testing & Adjusting Manual for this procedure.5. Install a new governor seal.Disassemble Fuel Ratio Control
Start By:a. remove fuel ratio control 1. Remove two bolts (1) and the housing (2). 2. Remove valve assembly (3).3. Remove seal (4) and O-ring seal from valve.4. Remove the retainer (5) and two springs (6). 5. Remove three bolts (9) and cover (10).6. Remove valve (7), diaphragm (8), retainer and spring. 7. Remove pin (12) from valve (7).8. Remove cover (11) from the valve.9. Remove the seal from the cover (11).Assemble Fuel Ratio Control
1. Put clean engine oil on lip of seal. Install the seal (1) in cover (2). Install seal so lip of seal is toward the inside of the cover. 2. Install the valve (3) into cover (2).3. Install the pin that holds cover on valve. 4. Install spring (7) and the retainer (6) in cover (8).5. Install diaphragm (5) on the valve assembly (4) and in the cover. 6. Install cover and three bolts (11) that hold covers together.7. Put clean engine oil on seal and ring seal. Install the seals (10) on valve.8. Install the two springs (13), retainer and valve assembly (12).9. Install housing (9) and two bolts.
Correct adjustment must be made to fuel ratio control before installation. See Systems Operation Testing & Adjusting for this procedure.
End By:a. install fuel ratio control