101482-9100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829100

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9100 1014829100

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Service parts 101482-9100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8150

3. GOVERNOR 105419-0790

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-2920

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4910

11. Nozzle and Holder 16600-54T01

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3390

14. NOZZLE

105017-0900

15. NOZZLE SET

Include in #1:

101482-9100 as INJECTION-PUMP ASSEMBLY

101491-0201 as _

Cross reference number

ZEXEL 101482-9100 1014829100

Zexel num

Bosch num

Firm num

Name

101482-9100

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 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 3.2 3.15 3.25

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 10.4

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 42.7 41.7 43.7

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 38.4 36.4 40.4

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 9.2+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 8 6 10

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_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 62 72

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the stopper bolt (at shipping).
----------

----------
a=(24deg)+-5deg b=(14deg)+-5deg c=(3deg)+-5deg

Stop lever angle

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

----------
a=56.5deg+-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=16deg
----------
a=(100deg)

Information:

In this manual, specifications, service standards, adjustment procedures, disassembly procedures, inspection procedures, and reassembly procedures for the engine are shown in groups. The contents of each group are listed in the index and at the beginning of that group. For instructions on operation and periodic inspection, refer to the operation manual. For instructions on ordering replacement parts, refer to the parts catalog. For information on the engine's structure and function, refer to relevant training material.Items Shown in this Manual
(1) Parts mentioned in the text and shown exploded views are numbered in their disassembly sequences.(2) Inspections to be preformed during disassembly are shown in
in the exploded views.(3) Service standards for inspection and repair operations are indicated at relevant places in the text and in a table in Group 2.(4) The sequences in which parts should be reassembled during reassembly operations are shown under reassembly drawings in this manner:
(5) The symbols and headings shown below are used in this manual to highlight particularly important and safety-critical instruction.
Indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property damage.
Indicates important information or information which is useful for engine operation or maintenance.(6) With regard to tightening torques, points to which engine oil must be applied are labeled "Wet". Where there is no such indication, parts should be tightened in a dry condition.Terms Used in This Manual
Terms used in this manual are defined as follows:(1) Front and RearThe term "front" refers to the fan side of the engine, and the term "rear" applies to the flywheel side.(2) Left and RightThe term "left" and "right" apply to the sides of the engine as seen from the flywheel.(3) Service Standards* Standard ValueThis term indicates a designed nominal dimension, the designed dimension of a single part, the standard clearance between two parts after assembly, or a standard performance value for an assembly.* LimitThis term indicates a value beyond which a part is no longer usable in terms of performance and strength and must be repaired or replaced.