101401-9020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019020 tf0713800

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9020 1014019020

MAZDA TF0713800 tf0713800

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Cross reference number

ZEXEL 101401-9020 1014019020

MAZDA TF0713800 tf0713800

Zexel num

Bosch num

Firm num

Name

101401-9020
101401-9027

TF0713800 MAZDA

INJECTION-PUMP ASSEMBLY
TF *

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 I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 160

Fixing the lever *

Injection quantity adjustment_05

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_06

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 *

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.
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T1=E03
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Speed control lever angle

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

Stop lever angle

N:Pump normal S:Engine stop (1)Use the hole at R = aa (2)Set the stop adjuster screw
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aa=39mm
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a=14deg+-5deg b=26deg+-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.
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Na=1825r/min Nb=325r/min Ra=6.5-0.5mm
----------

0000001601 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
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N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
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Ra=R1(12.6)mm Rb=(R1-0.4)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=64.6+-0.5cm3/1000st Q2=(56.4)+-1cm3/1000st

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=(140deg)

Information:

1. Turn the engine counterclockwise (as seen from the flywheel end of the engine) with Tool (A) until the No. 1 piston is at top center (TC) on the compression stroke. Install the timing bolt. Install 6V-2112 Timing Pin through the hole in the injection pump housing. See the topic "Finding Top Center Compression Position for NO. 1 Piston" in SENR6577 Testing & Adjusting. Tool (B), 6V-2112 Timing Pin, replaces 6V-6019 Timing Pin. 2. Remove two bolts (1).3. Remove eleven bolts (2) and cover (3). 4. Remove four bolts (5), retainer (6) and automatic timing advance (4).Install Automatic Timing Advance
1. Install automatic timing advance (4). Install retainer (6) and four bolts (5).2. Tighten the bolts (5) with fingers until there is a small amount of friction (slight drag) between the retainer and automatic timing advance (4). This friction will hold the unit against the timing gears. This prevents play (backlash) when gears are turned to the correct position.3. Remove the timing bolt. Turn the flywheel until the timing pin will go into the groove in the injection pump camshaft.4. With the timing pin installed, turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 30 degrees. The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center (TC).5. Turn the flywheel in the direction of engine rotation until the No. 1 piston of the engine is on top center compression stroke. Then turn the timing bolt into the threaded hole in the flywheel.6. Tighten bolts (5) to 25 N m (20 lb ft). Then remove the timing pin from the injection pump housing.7. Tighten bolts (5) to 135 7 N m (100 5 lb ft). Then remove the timing bolt from the flywheel.8. Turn the crankshaft two complete revolutions and check the timing again to see that timing pin will go into the groove in the injection pump camshaft with bolt in flywheel.9. If timing is not correct, do the procedure of Steps 1 through 7 again. If the timing is correct, be sure to remove the timing pin and the timing bolt. 5. Install eleven bolts (2) and cover (3).6. Install two bolts (1). Disassemble Automatic Timing Advance
Start By:a. remove automatic timing advance 1. Remove flange assembly (1). 2. Remove two springs (2) and two weights (3) from drive gear assembly (4). 3. Remove two slides (5) from pistons (6).4. Separate drive gear assembly (4) from advance sleeve (7).Assemble Automatic Timing Advance
1. Put weights (3) in position in flange assembly (1) as shown.2. Install springs (2) in flange assembly (1). 4. Use 1P-008 General Purpose Lubricant to hold slides (5) in position on drive gear assembly (4). Install slides (5) on pistons (6).5. Install advance sleeve (7) to drive gear assembly (4). 6. Install drive gear assembly (4) on flange assembly (1). Make sure slides (5) fit in grooves of the weights.End By:a. install automatic timing advance