Information injection-pump assembly
ZEXEL
101491-9274
1014919274
Rating:
Cross reference number
ZEXEL
101491-9274
1014919274
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+0.16
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
82.5
78.5
86.5
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.67
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
52.3
48.3
56.3
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
600
600
600
Rack position
R1-2.18
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1-0.98
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=C01 BCL=1.2+-0.1mm
----------
----------
T1=C01 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:
Start By:a. remove radiatorb. remove hydraulic pumpc. remove crankshaft pulleyd. remove alternatore. remove intake manifoldf. remove starting motorg. remove oil filterh. remove transmission
All wires, hoses, lines and linkage that is disconnected must be tied or wired out of the way to prevent damage when removing engine.
1. Identify and disconnect all electrical connections to the engine. Disconnect hydraulic lines and cab heater hoses. Disconnect all fuel lines and throttle controls. Tie or wire all wires, hoses, lines and linkage out of the way for engine removal.2. Remove front and rear engine mount bolts (1). 3. With the forks of a lift truck positioned together, position forks centered over the engine as illustrated. Install tooling (A) and then run a chain through the existing engine lifting eyes and tooling (A) as illustrated. Raise engine up slightly and start to remove engine. 4. With the engine part of the way out, remove four bolts (2) and remove rear mount bracket (3). Repeat step for the other rear mount bracket. With both rear mount brackets removed, finish removing engine. Weight of the engine is 340 Kg (750 lbs.). At the time of installation, tighten front mount bolts to a torque of 370 50 N m (270 37 lb.ft.) and rear mount bolts to a torque of 100 15 N m (75 11 lb.ft.). Install in the reverse order.End By:a. install transmissionb. install oil filterc. install starting motord. install intake manifolde. install alternatorf. install crankshaft pulleyg. install hydraulic pumph. install radiator
All wires, hoses, lines and linkage that is disconnected must be tied or wired out of the way to prevent damage when removing engine.
1. Identify and disconnect all electrical connections to the engine. Disconnect hydraulic lines and cab heater hoses. Disconnect all fuel lines and throttle controls. Tie or wire all wires, hoses, lines and linkage out of the way for engine removal.2. Remove front and rear engine mount bolts (1). 3. With the forks of a lift truck positioned together, position forks centered over the engine as illustrated. Install tooling (A) and then run a chain through the existing engine lifting eyes and tooling (A) as illustrated. Raise engine up slightly and start to remove engine. 4. With the engine part of the way out, remove four bolts (2) and remove rear mount bracket (3). Repeat step for the other rear mount bracket. With both rear mount brackets removed, finish removing engine. Weight of the engine is 340 Kg (750 lbs.). At the time of installation, tighten front mount bolts to a torque of 370 50 N m (270 37 lb.ft.) and rear mount bolts to a torque of 100 15 N m (75 11 lb.ft.). Install in the reverse order.End By:a. install transmissionb. install oil filterc. install starting motord. install intake manifolde. install alternatorf. install crankshaft pulleyg. install hydraulic pumph. install radiator