101491-9380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9380 1014919380

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Service parts 101491-9380 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9350

3. GOVERNOR 105921-2110

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105670-0250

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4090

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 16.7(170)

13. NOZZLE-HOLDER 105048-3050

14. NOZZLE

105017-0070

15. NOZZLE SET

Include in #1:

101472-3400 as _

101491-9380 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-9380 1014919380

Zexel num

Bosch num

Firm num

Name

101491-9380

DPICO

INJECTION-PUMP ASSEMBLY
SL * Q

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

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 51.5 51 52

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 9.8+-0.5

Pump speed r/min 325 325 325

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(11)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 51.5 51 52

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 60.5 56.5 64.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.05

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 37.6 33.6 41.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position (R1+0.15 )+-0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 32.5 28.5 36.5

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.15

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 59.7 55.7 63.7

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position 17++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 106 96 116

Fixing the lever *

Rack limit *

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
----------
T1=C33
----------

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.
----------

----------
a=40deg+-5deg b=40deg+-5deg

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:

Final Fuel Filter
The filter element collects and holds contaminants and cannot be washed or otherwise restored.To remove the used filter, proceed as follows:1. Stop the engine and close the diesel fuel line valve (if equipped).2. Unscrew and remove filter. 3. Clean the gasket sealing surfaces on the filter bases. 4. Lubricate the new filter gasket with clean diesel fuel.
Do not pour fuel into the new filter element before installing. Prime the system as instructed in the topic, PRIMING THE FUEL SYSTEM.
5. Tighten the filter by hand until the gasket contacts the base, then tighten 1/2 to 3/4 turn more.6. Start the engine and run at 1000 rpm for several minutes and check for leaks. If the engine fails to start, prime the fuel system. See the topic TO PRIME THE SYSTEM. Keep New Fuel Filters On Hand
Extra filters should be kept on hand for replacement. Always keep filters wrapped in their original carton to insure against dust and dirt accumulation which will shorten the life of the filters or may cause damage to the fuel injection equipment.To Prime The System
If air is trapped in the fuel system, the diesel engine will either not start, or will misfire. Then it is necessary to prime the system.The fuel priming pump is mounted on the fuel filter base. If the fuel filter is changed or if the engine has run out of fuel, prime the fuel system as follows: 1. Be sure the fuel line valve is open and the engine shutoff control is off.2. Unlock the fuel priming pump.3. Operate priming pump until increased resistance is felt.4. Lock fuel priming pump.If the engine fails to start or continues to misfire or smoke, further bleeding is necessary. With engine running, or with the use of the priming pump, loosen fuel line nuts, one at a time, several times in succession and allow fuel to run until free of air bubbles. Tighten fuel line nuts.
LOOSENING FUEL INJECTION LINE TO BLEED SYSTEMFuel Injection Equipment
When improper fuel injection is affecting engine operation, a systematic check should be made to determine the cause. The most likely cause is dirt or water in the fuel. Drain the sediment from the fuel tank. Check the fuel pressure gauge as mentioned in the topic, FUEL FILTERING SYSTEM. Replace the filters if necessary. Then prime the fuel system until clean fuel reaches the fuel injection pumps. If the fuel system is air bound, priming the system will overcome the difficulty.If the engine is running irregularly, smoking, or knocking, a fuel injection valve may not be spraying the fuel properly.Direct Injection System
The fuel system of direct injection engines is essentially the same as precombustion chamber engines. The absence of the precombustion chamber requires a different fuel nozzle and adapter. Externally the direct injection fuel nozzle resembles the precombustion chamber nozzle except it is longer in length. Nozzle testing and replacement procedure is the same as illustrated for the precombustion chamber engines, except that an extracting tool is used to remove