101441-9780 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419780

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101441-9780 1014419780

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Service parts 101441-9780 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8310

3. GOVERNOR 105419-1300

4. SUPPLY PUMP 105220-4950

5. AUTOM. ADVANCE MECHANIS 105622-1620

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105148-1120

11. Nozzle and Holder 16600-43G02

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105078-0050

14. NOZZLE

105007-1130

15. NOZZLE SET

Include in #1:

101441-9780 as INJECTION-PUMP ASSEMBLY

104302-6640 as _

Cross reference number

ZEXEL 101441-9780 1014419780

Zexel num

Bosch num

Firm num

Name

101441-9780

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

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 2.3 2.25 2.35

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 A

Rack position 11

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 32.8 31.8 33.8

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 9.5 8.4 10.6

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 52 47 57

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_02

Pump speed r/min 1100

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference from N = N1 (7)Rack difference to N = N2
----------
K=15 N1=1000r/min N2=1000r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Stopper bolt setting (2)At delivery (3)Confirmation
----------

----------
a=17deg+-5deg b=5deg+-5deg c=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(100deg)

Information:

Illustration 1 g00596626
(1) Potentiometer (2) Light Emitting Diode (3) The Normally Closed Contact (4) Common Contact (5) Normally Open Contact
Preset the variable voltage power supply to 22 VDC.
Secure the variable voltage power supply.
Use the 4P-4029 Adjustment Tool to turn the potentiometer for the low voltage alarm module counterclockwise. Turn the potentiometer 25 times.
Remove the wire from the low voltage alarm module's positive terminal. Remove the wire from the low voltage alarm module's negative terminal.
Connect the power supply's positive lead to the low voltage alarm module's positive terminal.
Connect the power supply's negative lead to the low voltage alarm module's negative terminal.
Connect the multimeter to the N.O. contact and connect the multimeter to the COM contact. Set the multimeter to the function for measuring ohms. The multimeter should read "OL".
Energize the power supply.
Verify that the voltage is 22 VDC.
If the voltage is not 22 VDC, adjust the power supply.
Slowly turn the potentiometer for the low voltage alarm module clockwise until the LED illuminates.Note: The relay will energize after the LED illuminates. This occurs in 50 15 seconds.
Observe the multimeter in order to verify that the relay energized. The resistance reading should be low when the relay is energized.
Increase the output of the power supply to 24 VDC.Note: The LED and the relay de-energize simultaneously.
Remove the power supply's negative lead from the low voltage alarm module.
Remove the power supply's positive lead from the low voltage alarm module.
Remove the multimeter's leads from the low voltage alarm module.
Connect the system's wire to the low voltage alarm module's positive terminal. Connect the system's wire to the low voltage alarm module's negative terminal.