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101401-9152 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019152


 

Information injection-pump assembly

ZEXEL 101401-9152 1014019152
101401-9152 INJECTION-PUMP ASSEMBLY
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Service parts 101401-9152 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-8970
3. GOVERNOR 105492-7160
4. SUPPLY PUMP 105210-4870
5. AUTOM. ADVANCE MECHANIS 105622-1761
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5121
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-4740
15. NOZZLE SET

Include in #1:

101401-9152 as INJECTION-PUMP ASSEMBLY
106672-3720 as _
106672-3721

Cross reference number

ZEXEL 101401-9152 1014019152


Zexel num
Bosch num
Firm num
Name
101401-9152 
 
   
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   131424-1520
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   3.6 3.55 3.65
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   11.2
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   92.2 90.2 94.2
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   8.5+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   8.4 6.9 9.9
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   94 94
Fixing the lever   *
Remarks
After startup boost setting  
Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks
Start  
Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1600
Advance angle deg.   5 4.5 5.5
Remarks
Finish  

Test data Ex:

Governor adjustment

Test data 101401-9152
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting
----------
RT=1 TH=2.2mm SXL=11.7+-0.1mm N1=500r/min
----------

Speed control lever angle

Test data 101401-9152
F:Full speed
----------

----------
a=20.5deg+-5deg

0000000901

Test data 101401-9152
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=29.5deg+-3deg

Stop lever angle

Test data 101401-9152
N:Normal S:Stop
----------

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

Test data 101401-9152
(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=18deg
----------
a=(90deg)




Information:

1. Disconnect hose (1) at governor control cylinder (2).2. Remove pin (4).3. Remove governor control cylinder (2).4. Note the position of linkage (3) in the lever, and remove linkage (3). The following steps are for installation of the governor control cylinder.5. Adjust linkage (3) so the distance between rod end centers is 84.07 mm (3.309 in).6. Install linkage (3) in its original position in the lever.7. Be sure lever (5) on the governor shaft is at 15 degrees from vertical (CW when viewed from the left side of the machine) with engine at low idle.8. Install control cylinder (2). Install pin (4) through link (3) and lever (5).9. Connect hose (1) to governor control cylinder (2).10. Adjust linkage (3) so lever (5) is at low idle when governor control cylinder is fully retracted.Disassemble & Assemble Governor Control Cylinder
Start By:a. remove governor control cylinder 1. Remove cover (1).
A spring force of 44.5 N (10 lb) will be released when the bolt that holds piston (8) is removed. Hold the components of the governor control cylinder to prevent unexpected movement of components and personal injury.
2. Remove the bolt that holds piston (6), and remove the piston and springs.3. Remove O-ring seal (2) and sleeve (5).4. Remove seals (3) and (4) from piston (6). The following steps are for the assembly of the governor control cylinder.5. Install lip-type seal (3) and "T" seal on the piston (6). Install the lip-type seal with the lip facing the cylinder pressure source.6. Install shell (5) in the air chamber body.7. Put 5P-0960 Multipurpose Grease inside the shell.8. Carefully install piston (6) and springs into the air chamber body.9. Install the bolt to hold the piston.10. Install O-ring seal (2) and cover (1).End By:a. install governor control cylinder

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Group cross 101401-9152 ZEXEL

101401-9150  
 
 
INJECTION-PUMP ASSEMBLY
101401-9151  

101401-9152 
F 019 Z10 469 
 
INJECTION-PUMP ASSEMBLY
101401-9152  
 
 
INJECTION-PUMP ASSEMBLY
101401-9153  
 
 
INJECTION-PUMP ASSEMBLY

China 

101401-9154  
9 400 613 793 
 
INJECTION-PUMP ASSEMBLY
4102BQ
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