Information injection-pump assembly
ZEXEL
101402-9150
1014029150
YANMAR
12644051010
12644051010
Rating:
Cross reference number
ZEXEL
101402-9150
1014029150
YANMAR
12644051010
12644051010
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-4-3
Pre-stroke
mm
3.8
3.75
3.85
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10
Pump speed
r/min
900
900
900
Each cylinder's injection qty
mm3/st.
117.3
115.5
119.1
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.4+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
15
14
16
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Each cylinder's injection qty
mm3/st.
134
134
164
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)RACK LIMIT
(3)Idle sub spring setting: L1.
----------
K=20 L1=5.2-0.5mm
----------
----------
K=20 L1=5.2-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
----------
----------
a=(20deg)+-5deg b=(38deg)+-5deg
----------
----------
a=(20deg)+-5deg b=(38deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=53deg+-5deg
----------
----------
a=20deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
START BY:a. remove timing gear coverb. remove fuel injection pump housing and governor 1. Remove four bolts (2), plate (3) and idler gear (1). 2. If the camshaft is not going to be remove, use tooling (A) to remove camshaft gear (4).
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear.Install Timing Gears And Plate
1. Install a new gasket on the timing gear plate.2. Put timing gear plate (1) in position on the cylinder block, and install the bolts that hold the timing gear plate to the cylinder block. 3. Heat camshaft gear (2) to a maximum temperature of 315°C (600°F), and install it on the camshaft. 4. Use tooling (A), and install the bearing in the idler gear. Set the gear on the front face (face with timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in.) below the rear face of the idler gear.5. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (4) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (3) of the camshaft gear can be seen at the outer edges of the idler gear.END BY:a. install fuel injection pump housing and governorb. install timing gear cover
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear.Install Timing Gears And Plate
1. Install a new gasket on the timing gear plate.2. Put timing gear plate (1) in position on the cylinder block, and install the bolts that hold the timing gear plate to the cylinder block. 3. Heat camshaft gear (2) to a maximum temperature of 315°C (600°F), and install it on the camshaft. 4. Use tooling (A), and install the bearing in the idler gear. Set the gear on the front face (face with timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in.) below the rear face of the idler gear.5. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (4) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (3) of the camshaft gear can be seen at the outer edges of the idler gear.END BY:a. install fuel injection pump housing and governorb. install timing gear cover