Information injection-pump assembly
ZEXEL
101491-9272
1014919272
MAZDA
Z02SL5013800
z02sl5013800
Rating:
Cross reference number
ZEXEL
101491-9272
1014919272
MAZDA
Z02SL5013800
z02sl5013800
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
12.77
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
73.2
72.7
73.7
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
-
Rack position
10.1
Pump speed
r/min
340
340
340
Average injection quantity
mm3/st.
10
8
12
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.77
)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
73.2
72.7
73.7
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.4
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
83.8
79.8
87.8
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.86
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
50
46
54
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
75
70
85
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
625
625
625
Rack position
R1-2.31
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
625
625
625
Rack position
R1-1.11
Boost pressure
kPa
11.3
11.3
11.3
Boost pressure
mmHg
85
85
85
Timer adjustment
Pump speed
r/min
1500+-25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1750
Advance angle
deg.
3
2.7
3.3
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=B80 BCL=1.2+-0.1mm
----------
----------
T1=B80 BCL=1.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=20deg+-5deg b=(43deg)+-3deg
----------
----------
a=20deg+-5deg b=(43deg)+-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. Remove the bolts that hold timing gear case cover (1) to the timing gear case. Remove the timing gear case cover.
Later type crankshaft front seals (with protruding dust lip) do not use a slinger. Seal damage can occur if a slinger is used.
2. On earlier models, remove slinger (2). 3. Remove seal (3) from timing gear case cover (1).Install Timing Gear Case Cover
*New, improved crankshaft front oil seals have a dust lip protrusion molded on to the front of the seal. The centering tool (PD162) must be reworked as shown in this illustration to prevent damage to this dust lip when the new type seal is installed. 1. Put timing gear case cover (1) in position with a new gasket. Install the bolts and lockwashers that hold it, but do not tighten them at this time. Use tool (A) to properly locate the timing gear case cover with respect to the crankshaft.2. Install tool (A) over the crankshaft and into the timing gear case cover seal bore. Hold tool (A) firmly in the timing gear case cover. Tighten the bolts that hold the timing gear case cover.
Washer (2) replaces the slinger, which is not used on later type seals with protruding dust lip.
3. Install washer (2). 4. Put seal (3) in position in the timing gear case cover. Install the seal with the lip toward the crankshaft gear. The seal surface must be clean and dry. Do not handle the lip of the seal.5. Use tool (A) and a soft hammer to install seal (3). Install the seal until it is 3.17 mm (.125 in) below the surface of the timing gear case cover.End By:a. install crankshaft pulleyb. install fan assembly
Later type crankshaft front seals (with protruding dust lip) do not use a slinger. Seal damage can occur if a slinger is used.
2. On earlier models, remove slinger (2). 3. Remove seal (3) from timing gear case cover (1).Install Timing Gear Case Cover
*New, improved crankshaft front oil seals have a dust lip protrusion molded on to the front of the seal. The centering tool (PD162) must be reworked as shown in this illustration to prevent damage to this dust lip when the new type seal is installed. 1. Put timing gear case cover (1) in position with a new gasket. Install the bolts and lockwashers that hold it, but do not tighten them at this time. Use tool (A) to properly locate the timing gear case cover with respect to the crankshaft.2. Install tool (A) over the crankshaft and into the timing gear case cover seal bore. Hold tool (A) firmly in the timing gear case cover. Tighten the bolts that hold the timing gear case cover.
Washer (2) replaces the slinger, which is not used on later type seals with protruding dust lip.
3. Install washer (2). 4. Put seal (3) in position in the timing gear case cover. Install the seal with the lip toward the crankshaft gear. The seal surface must be clean and dry. Do not handle the lip of the seal.5. Use tool (A) and a soft hammer to install seal (3). Install the seal until it is 3.17 mm (.125 in) below the surface of the timing gear case cover.End By:a. install crankshaft pulleyb. install fan assembly