101491-0554 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910554

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-0554 1014910554

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Service parts 101491-0554 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8720

3. GOVERNOR 105931-8060

4. SUPPLY PUMP 105210-5140

5. AUTOM. ADVANCE MECHANIS 105671-0160

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5122

11. Nozzle and Holder 8-97021-703-1

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0610

15. NOZZLE SET

Include in #1:

101491-0554 as INJECTION-PUMP ASSEMBLY

101602-3040 as _

Cross reference number

ZEXEL 101491-0554 1014910554

Zexel num

Bosch num

Firm num

Name

101491-0554

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 3.8 3.75 3.85

Rack position
After adjusting injection quantity. R=A

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 -

Rack position 12.2

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 57.1 55.5 58.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 13.3 12 14.6

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.2)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 57.1 56.1 58.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position -

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 68 64 72

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 92 92 124

Fixing the lever *

Timer adjustment

Pump speed r/min 1530--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1480

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1775

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)At delivery (at R = A, N = N1)
----------
T1=F44 N1=100r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Set the idle side stopper bolt so that speed = bb and rack position = cc (at delivery). (3)Stopper bolt set position 'H'
----------
aa=50mm bb=100r/min cc=R1(12.2)mm
----------
a=(23.5deg) b=27.5deg+-5deg c=(33deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.8+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(100deg)

Information:

(1) Inside diameter of rocker arm ... 19.063 to 19.101 mm (.7505 to 7520 in) Lever clearance on rocker shaft ... 0.03 to 0.089 mm (.001 to .0035 in)Maximum permissible clearance (worn) ... 0.13 mm (.005 in)(2) Diameter of rocker shaft ... 19.012 to 19.037 mm (.7485 to .7495 in)(3) Install seal (3) in cylinder head before rocker shaft is installed.(4) Length of push rods ... 270.46 to 271.98 mm (10.648 to 10.708 in) Diameter of push rods ... 7.87 to 7.92 mm (.310 to .312 in)(5) End play of camshaft (new) ... 0.10 to 0.41 mm (.004 to .016 in) Maximum permissible end play (worn) ... 0.51 mm (.020 in)(6) Torque for bolt that holds camshaft gear on camshaft ... 70 N m (50 lb ft)(7) Camshaft thrust washer. A new cylinder block, camshaft and thrust washer have been introduced on the 4.236 engine for the Backhoe Loaders. The thrust washer recess in the new block is deeper. The thrust washer thickness remains the same. The change became effective with engine serial number LD70178U106654N. The engine serial number is located above the fuel injection pump on the block.Outside diameter of thrust washer ... 72.95 to 73.00 mm (2.872 to 2.874 in)Cylinder block recess diameter for thrust washer ... 73.03 to 73.28 mm (2.875 to 2.885 in)Clearance of thrust washer in recess ... 0.03 to 0.33 mm (.001 to .013 in)Inside diameter of thrust washer ... 44.45 mm (1.750 in)Thickness of thrust washer ... 5.49 to 5.54 mm (.216 to .218 in) The recess in the cylinder block is deeper for current models.Earlier Models:Cylinder block recess depth for thrust washer ... 4.75 to 4.83 mm (.187 to .190 in)Projection of thrust washer above cylinder block front face ... 0.66 to 0.79 mm (.026 to .031 in)Current Models:Cylinder block recess depth for thrust washer ... 5.38 to 5.49 mm (.212 to .216 in)Projection of thrust washer above cylinder block front face ... 0.0 to 0.13 mm (0.0 to .005 in)(8) Diameter of camshaft journals: No. 1 journal ... 50.71 to 50.737 mm (1.9965 to 1.9975 in)Minimum permissible diameter ... 50.660 mm (1.9945 in)No. 2 journal ... 50.457 to 50.483 mm (1.9865 to 1.9875 in)Minimum permissible diameter ... 50.406 mm (1.9845 in)No. 3 journal ... 49.949 to 49.975 mm (1.9665 to 1.9675 in)Minimum permissible diameter ... 49.898 mm (19.9645 in)See Cylinder Block for camshaft bore specifications.(9) Tappet (valve lifter): Length of tappet ... 75.4063 mm (2.96875 in)Shank diameter ... 18.987 to 19.012 mm (.7475 to .7485 in)Diameter of bore in block for tappet ... 19.05 to 19.083 mm (.750 to .7513 in)Running clearance between tappet and block ... 0.038 to 0.097 mm (.0015 to .0038 in)Foot diameter of tappet ... 30.163 mm (1.1875 in) Camshaft lobe height: 1. Measure base circle (C).2. Add lobe lift (A) to base circle measurement. Camshaft lobe lift (A) is ... 7.62 to 7.70 mm (.300 to .303 in)3. Total is camshaft lobe height (B). Minimum