101491-9230 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919230

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9230 1014919230

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101491-9230 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 101491-9230 1014919230

Zexel num

Bosch num

Firm num

Name

101491-9230

MAZDA

INJECTION-PUMP ASSEMBLY
SL *

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 3.4 3.35 3.45

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 11.28+-0 .02

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 57.7 57.2 58.2

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 9.3+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9 7 11

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 11.28+-0 .5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 57.7 57.2 58.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position 11.55+-0 .5

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 70 68 72

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 11.39+-0 .5

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 42.9 40.9 44.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 15++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 106 96 116

Fixing the lever *

Timer adjustment

Pump speed r/min 1350+-25

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1700

Advance angle deg. 3.5 3.2 3.8

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: R1, speed N1 (3)Torque cam set point
----------
T1=A19 R1=+-0.02mm N1=+-3r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=20deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Engine normal (2)Engine stop (3)Set the speed to aa using the idle lever and then confirm non-injection. (4)(Actual measurement) (5)Set the normal set bolt.
----------
aa=300r/min
----------
a=40deg+-5deg b=23deg+-5deg c=(17deg)+-5deg

0000001501 GOV RACK POSITION CONFIRM

Confirm the governor adjustment rack position. Standard point A Set the torque cam B. (C) Confirmation (D) Remarks (N): Speed of the pump (R) Rack position (mm)
----------

----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.28+-0.02mm Rb=11.39+-0.02mm Rc=11.34+-0.1mm Rd=11.55+-0.05mm Re=11.46+-0.05mm Rf=11.53+-0.05mm

0000001601 LEVER

f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever Stop lever's normal position setting method 1. (1) Push in the set bolt (A) until the rack starts to move. (2)Return the bolt N1 turns from that position and set. 2. Rack with limiter (1)Return the bolt N1 turns from the rack limit position and set.
----------
N1=1.5
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(130deg)

Information:

Installation of Nozzles, Ether Supply Tubes and Connectors
1. If the machine does not already have an ether aid starting system, remove the plug from each turbocharger outlet adapter (2) and (3). Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (1) where each plug was removed. 2. When installing each nozzle assembly (1), the indicator mark at location (A) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).3. Install 6Y1575 Tube Assembly (4) in the front nozzle and 6Y1576 Tube Assembly (6) in the rear nozzle as shown. Connect tube assemblies (4) and (6) to 8C9006 Tee (5). 4. Put 6Y1770 Tube Assembly (7) in position along the cylinder block and connect it to 8C9006 Tee (5) as shown. Install a 5P6312 Union (8) at the loose end as shown.5. Locate and attach 6V2686 Clips at locations (B) and (C), to secure tube (7) in position.6. Tighten the bolts that secure the clips at locations (B) and (C). 7. Put 5P0580 Tube (9) in position for connection to 5P6312 Union (8) that was JUST installed at the end of tube assembly (7). Position the tube assembly alongside chassis wiring harness (10) and up to the shuttle valve in cover assembly (11).Cut the 5P0580 Tube to length. Put a 5P6313 Nut and a 5P6314 Sleeve on the end of the piece of tube. Connect the end of the tube to union (8) and tighten the nut.
Be careful and DO NOT overtighten the nut. Overtightening the nut could crush the tube.
8. Use 3S2093 Straps (12) to fasten tube (9) to chassis wiring harness (10) [there are actually twelve straps between union (8) and the fender, and three straps inside of cover assembly (11)]. 9. Connect the end of tube (9) to elbow (13) in the outlet port of the shuttle valve. 10. If all welding procedures have been completed proceed as follows: * Apply the 9X4542 Ether Aid Identification Film (English) on the ECU. (If an Ether Aid Identification Film is needed for a language other than English, refer to the chart that follows for the part number to order to obtain a film with a specific language.) * Use four 5M3062 Bolts with 8T4896 Washers to fasten 9X5303 ECU (14) to the mounting bars inside cover assembly (11).* Connect the terminal on the loose end of fabricated wire assembly (15) (previously installed when mounting bars were installed inside the cover assembly) to one of the ECU mounting bolts as shown.* Connect the 30 pin connector of chassis wiring harness (10) to ECU (14).11. Use the dimensions shown to install 9X6191 Film (16).12. Put a 5P1075 Washer over the end of the 7S2043 Knob Assembly. Put the end of the knob assembly through the door of cover assembly (11). Install the 9S8230 Plate Assembly over the shaft of the knob assembly, then insert the 4H1641 Pin in the hole in the shaft.Installation of Ether Cylinders
1. Turn the disconnect switch