101401-9201 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019201

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9201 1014019201

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Service parts 101401-9201 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9881

3. GOVERNOR 105921-6180

4. SUPPLY PUMP 105210-3300

5. AUTOM. ADVANCE MECHANIS 105671-0091

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5561

11. Nozzle and Holder TF32 13 H50A

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

13. NOZZLE-HOLDER 105048-3450

14. NOZZLE

105017-1360

15. NOZZLE SET

Include in #1:

101401-2363 as _

101401-9201 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101401-9201 1014019201

Zexel num

Bosch num

Firm num

Name

101401-9201

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 12.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.6 66.1 67.1

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(12.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.6 66.1 67.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point C

Rack position R1-0.4

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 49.7 45.7 53.7

Fixing the lever *

Injection quantity adjustment_05

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=H12
----------

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
----------

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.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(12.7)mm Rb=R1-0.4mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=66.6+-0.5cm3/1000st Q2=-

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:

Start By:a. remove oil pump 1. Check each connecting rod cap for its location on the crankshaft. Each cap must have a number (1) which is the same as the number on the connecting rod. Do not mix bearings.2. Turn the crankshaft until two of the pistons are at bottom center.3. Remove connecting rod caps (2). Remove the lower bearing from the connecting rod caps.4. Push the connecting rods away from the crankshaft and remove the upper bearings from the connecting rods.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
5. Install the upper bearings in connecting rods. put clean engine oil on the bearings and on the crankshaft journals. Slowly pull the connecting rods on the crankshaft.6. Put clean oil on the lower bearings. Install the lower bearings in the connecting rod caps. Be sure tab (3) on the back of the bearings fits in the groove of the caps and connecting rods. 7. Check the bearing clearance with Plastigage (A) as follows:a. Put clean oil on the threads of bolts (4). Install caps (5), Tool (A) and nuts finger tight.b. Tighten each nut (6) to a torque of 80 8 N m (60 6 lb ft).c. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees more. 8. Remove caps (5) and Plastigage (A). Make sure the connecting rod bearing caps are installed with their identification number in arrangement with the connecting rod number.
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
9. Measure the thickness of the Plastigage to find the bearing clearance. the clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in). The maximum clearance for used bearings is 0.25 mm (0.010 in).10. Install caps (5). Tighten nuts (6) to a torque of 80 8 N m (60 6 lb ft). Tighten the nuts 120 degrees more.11. Do Steps 1 through 10 for the other connecting rod bearings.End By:a. install oil pump