101482-9231 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829231

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9231 1014829231

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Service parts 101482-9231 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8150

3. GOVERNOR 105419-0440

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-6020

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:

101342-9000 as _

101482-9231 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101482-9231 1014829231

Zexel num

Bosch num

Firm num

Name

101482-9231

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 131424-1520

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 10.7

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 51.5 50.5 52.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

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_03

Adjusting point C

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)Tolerance for racks not indicated: +-0.05 (3)RACK LIMIT (4)Main spring setting (5)Set idle sub-spring
----------
K=13
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the stopper bolt at delivery (2)Confirmation
----------

----------
a=13deg+-5deg b=3deg+-5deg c=23deg+-5deg

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)- (4)-
----------

----------
a=(100deg)

Information:

Fuel Filter
(For in-line fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump and fuel hoses.
(For distributor-type fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump and fuel hoses.
Fuel Injection Pipe, Fuel Leak-Off Pipe and Fuel Injection Nozzle
(For in-line fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump, nozzle inlet connectors and injection pipes.
(For distributor-type fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump, nozzle inlet connectors and injection pipes.
Fuel Injection Pump
(In-line fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump.
(Distributor-type fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the injection pump.
Removal of Fuel Injection Pump
(1) Check the alignment marks stamped on the flange of the fuel injection pump and the pump mounting flange.(2) Remove the front cover from the engine.(3) Place alignment marks on the fuel injection pump gear and idler gear.(4) Unscrew the mounting bolts from the fuel injection pump flange, and remove the fuel injection pump together with the flange from the front plate. (a) After the fuel injection pump is removed, do not turn the engine.(b) When removing the pump gear, loosen the gear retaining nut while the pump is mounted on the engine.
Removal of fuel injection pump (1)
Removal of fuel injection pump (2)