101482-9130 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829130

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9130 1014829130

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Cross reference number

ZEXEL 101482-9130 1014829130

Zexel num

Bosch num

Firm num

Name

101482-9130

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 132424-0620

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 2.8 2.75 2.85

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 10.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 74.4 73.4 75.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8 12

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. 81 81 91

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT
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K=7
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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----------
a=(14deg)+-5deg b=(35deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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----------
a=26.5deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
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L=5.5mm
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a1=A a2=B a3=C a4=- r1=- r2=1100r/min r3=- r4=- Q1=- Q2=74.4+-1mm3/st Q3=- Q4=- c1=- c2=+-3.5% c3=- c4=- a5=25 a6=24 a7=23 a8=22 a9=21 a10=- a11=- a12=- a13=- a14=- a15=- r5=1250r/min r6=1200r/min r7=1150r/min r8=1100r/min r9=1050r/min r10=- r11=- r12=- r13=- r14=- r15=- R5=1340+-31r/min R6=1290+-30r/min R7=1235+-28r/min R8=1180+-27r/min R9=1130+-26r/min R10=- R11=- R12=- R13=- R14=- R15=-

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'P') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
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a=(60deg)

Information:

Overview of Lubrication System
Flow of oilOil Pump, Relief Valve, and Oil Pressure Switch
Disassembly
Removal sequence and points to check on oil pump(1) Oil filter(2) Oil pump(3) Gasket(4) Oil pump cover(5) Inner rotor(6) Outer rotor (the inner and outer rotors from a rotor assembly)(7) O-ring(8) Oil pump body(9) Relief valve(10) Oil pressure switch Key Points For Disassembly(1) Oil Pump
Remove the oil pump (parts (3) through (8) in the above illustration) as an assembly.
Removing oil pump(2) Oil Pressure Switch
Remove the switch using the Oil Pressure Switch Socket Wrench (MD998054).
Removing oil pressure switchInspection and Repair
(1) Oil Pump
(a) Using a thickness gauge, measure the clearance between the outer rotor and pump body. If the measurement exceeds the limit, replace the rotor assembly.Unit: mm (in.)
Measuring outer rotor-to-pump body clearance(b) Using a thickness gauge, measure the clearance between the outer rotor and the inner rotor. If the measurement exceeds the limit, replace the rotor assembly.Unit: mm (in.)
Measuring outer rotor-to-inner rotor clearance(c) Using a thickness edge and a thickness gauge, measure the clearance between the rotors and pump cover. If the measurement exceeds the limit, replace either the rotors or the pump body.Unit: mm (in.)
Measuring clearance between rotors and pump cover(2) Oil Pressure Switch
(a) Connect a tester (set to the ohm range) between the terminal and body of the oil pressure switch. There should be no continuity. If there is continuity, the switch is faulty and should be replaced.
Inspecting oil pressure switch(b) Insert a thin rod into the oil hole in the switch body. When the rod is then pushed in gently, there should be continuity between the switch body and terminal. If there is no continuity, the switch is faulty and should be replaced.(c) apply an air pressure of 49 kPa {0.5 kgf/cm2) (7.1 psi) to the switch through the oil hole. If there is continuity, the switch is normal. Simultaneously, check for air leakage. Any air leakage means that the diaphragm is broken and, therefore, the switch should be replaced.
Inspecting oil pressure switchAssembly
Point to note during reassembly of oil pumpPerform assembly by following the disassembly sequence in reverse: Key Points For Reassembly
Oil Pressure Switch
(a) Install the switch using the Oil Pressure Switch Socket Wrench (MD998054).(b) Before installation, apply sealant to the threads of the switch. (Use either Hermeseal H1 or ThreeBond 1104).
Installing Oil Pressure Switch
(a) Avoid applying sealant excessively to prevent it from reaching the end of the threads.(b Never tighten the switch to a torque exceeding specification.