Information injection-pump assembly
ZEXEL
101491-9270
1014919270
Rating:
Cross reference number
ZEXEL
101491-9270
1014919270
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-3420
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.1
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
69.8
68.3
71.3
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
300
300
300
Average injection quantity
mm3/st.
8
6
10
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(12.1)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
69.8
68.8
70.8
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1-0.15
)
Pump speed
r/min
1700
1700
1700
Average injection quantity
mm3/st.
77.1
73.1
81.1
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
84.5
74.5
94.5
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R2-1.1
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R2(R1-0.
3)
Boost pressure
kPa
6.7
6.7
6.7
Boost pressure
mmHg
50
50
50
Timer adjustment
Pump speed
r/min
850+-25
Advance angle
deg.
1
0.7
1.3
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
925
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1400+-25
Advance angle
deg.
0
0
0
Timer adjustment_04
Pump speed
r/min
1700+-25
Advance angle
deg.
3.5
3.2
3.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B61 BCL=1.1+-0.1mm
----------
----------
T1=B61 BCL=1.1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=20deg+-5deg b=45deg+-3deg
----------
----------
a=20deg+-5deg b=45deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Stop
(3)Stopper bolt setting
(4)Set the speed to aa using the idle lever and then confirm non-injection.
----------
aa=300r/min
----------
a=(15deg)+-5deg b=(13.5deg) c=23deg+-5deg d=40deg+-5deg
----------
aa=300r/min
----------
a=(15deg)+-5deg b=(13.5deg) c=23deg+-5deg d=40deg+-5deg
0000001501 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
----------
----------
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)
----------
----------
a=(130deg)
Information:
1. Disconnect electrical plug (1) and throttle linkage (2).2. Disconnect six fuel lines (3) from injection pump. 3. Remove inspection plate (5) from the timing gear cover. 4. Make an alingment of the timing marks on fuel injection pump gear (7) and idler gear (6), or put identification marks on the gears for correct installation. 5. Remove three bolts (8) that hold the fuel injection pump drive gear to the fuel injection pump.
Typical Example6. Put alignment marks on the fuel injection pump and the timing gear case cover as shown. Remove three nuts (9) and washers that hold the fuel injection pump in place. Remove fuel injection pump (10). Remove the gasket from the timing gear case. The following steps are for the installation of the fuel injection pump.7. Put the gasket for fuel injection pump (10) in position on the timing gear case. 8. Position the fuel injection pump; be sure dowel (11) in fuel injection pump gear (7) is in alignment with the groove (slot) in the fuel injection pump shaft when the fuel injection pump is put in position.
Typical Example9. For initial fuel injection pump timing, make an alignment of the reference marks on the fuel injection pump and the timing gear case. Install the three nuts (9) and washers that hold fuel injection pump (10) in place. 10. Be sure the timing marks or the marks that were put on the fuel injection pump gear and idler gear are in alignment. Install three bolts (8) that hold the fuel injection pump gear to the fuel injection pump. 11. Install plate (5) with a new gasket.12 Connect all fuel lines (3), control linkage (2) and electrical plug (1).13. Prime the fuel system. See the MAINTENANCE MANUAL.
Typical Example6. Put alignment marks on the fuel injection pump and the timing gear case cover as shown. Remove three nuts (9) and washers that hold the fuel injection pump in place. Remove fuel injection pump (10). Remove the gasket from the timing gear case. The following steps are for the installation of the fuel injection pump.7. Put the gasket for fuel injection pump (10) in position on the timing gear case. 8. Position the fuel injection pump; be sure dowel (11) in fuel injection pump gear (7) is in alignment with the groove (slot) in the fuel injection pump shaft when the fuel injection pump is put in position.
Typical Example9. For initial fuel injection pump timing, make an alignment of the reference marks on the fuel injection pump and the timing gear case. Install the three nuts (9) and washers that hold fuel injection pump (10) in place. 10. Be sure the timing marks or the marks that were put on the fuel injection pump gear and idler gear are in alignment. Install three bolts (8) that hold the fuel injection pump gear to the fuel injection pump. 11. Install plate (5) with a new gasket.12 Connect all fuel lines (3), control linkage (2) and electrical plug (1).13. Prime the fuel system. See the MAINTENANCE MANUAL.