101491-9580 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919580

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9580 1014919580

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Service parts 101491-9580 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9410

3. GOVERNOR 105921-3330

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105670-0080

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4091

11. Nozzle and Holder SL0113640A

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

13. NOZZLE-HOLDER 105048-3121

14. NOZZLE 105017-2070

15. NOZZLE SET

Include in #1:

101491-9580 as INJECTION-PUMP ASSEMBLY

106692-4403 as _

Cross reference number

ZEXEL 101491-9580 1014919580

Zexel num

Bosch num

Firm num

Name

101491-9580

INJECTION-PUMP ASSEMBLY

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 11.21+-0 .02

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 56.8 56.3 57.3

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 9.3+-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 11.21+-0 .5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 56.8 56.3 57.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position 11.48+-0 .5

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 68.9 66.9 70.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 11.32+-0 .5

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 42 40 44

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 16.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 96

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 (2)Tolerance for racks not indicated: R1, speed N1 (3)RACK LIMIT
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=20deg+-5deg b=41deg+-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=325r/min
----------
a=(15deg)+-5deg b=(13.5deg) c=23deg+-5deg d=40deg+-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)
----------

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Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.21+-0.02mm Rb=11.32+-0.02mm Rc=11.27+-0.1mm Rd=11.48+-0.05mm Re=11.39+-0.05mm Rf=11.46+-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
----------

0000001701 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=(11.21)mm Rb=(10.8)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=56.8+-0.5cm3/1000st Q2=48.8+-1cm3/1000st

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:

Use fuel consumption, service hours, or calendar time, whichever occurs first, to determine maintenance intervals. Experience has shown that maintenance intervals are most accurately scheduled on the basis of fuel consumed rather than service hours.Daily
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Clutch - Check/Adjust/Lubricate Air Starter & Air Tank (if equipped) - Check/Adjust/Drain water Engine Air Cleaner - Check service indicator SR4 Generator - Inspect/CheckEvery 1,100 L (300 gal) of Fuel or 50 Service Hours*
Dust Collector - Clean Light Duty Air Cleaner (If Equipped) - ReplaceEvery 2,800 L (750 gal) of Fuel 125 Service Hours*
Clutch - Check/Adjust/Lubricate Generator Space Heaters (If Equipped) - CheckEvery 5,600 L (1,500 gal) of Fuel or 250 Service Hours*
Scheduled Oil Sampling (S O S)1 - Obtain Sample Engine Oil and Filter(s)1 - Change Crankcase Breather1 - Clean Engine Valve Lash (Between First 250 and 1000 Service Hours Only)1 - Check/Adjust Cooling System - Test for supplemental coolant additive concentration Fuel System - Clean/Replace filters, Drain water from fuel tank Radiator Fins, Aftercooler, Belts, and Hoses - Inspect/Check Fan Drive Bearing - Lubricate Batteries - Check/Clean Magnetic Pickup (At First Oil Change Only - Inspect/Clean1These maintenance requirements are to be performed between the 250 and the 1000 Service Hour interval for Turbocharged (T) Engines ONLY. Refer to 500 Hour interval for Naturally Aspirated (NA) Engines.Every 11,250 L (3,000 gal) of Fuel or 500 Service Hours (NA Only)*
Scheduled Oil Sampling (S O S) Analysis - Obtain Sample Engine Oil and Filter(s) - Change Crankcase Breather - Clean Engine Valve Lash (Between First 500 and 1000 Service Hours Only) - Check/AdjustEvery 22,500 L (6,000 gal) of Fuel or 1000 Service Hours*
Engine Protection Devices - Inspect SR4 Generator and Control Panel - Inspect Fuel Control Linkage - LubricateEvery 45,000 L (12,000 gal) of Fuel 2000 Service Hours*
Engine Valve Lash, Valve Rotators, Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust Fuel Injection Nozzles - Test/Clean/Replace Turbocharger - Inspect Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect SR4 Generator - Check/Inspect Clean/LubricateEvery 68,220 L (18,000 gal) of Fuel or 3000 Service Hours or Two Years*
Cooling System - Add Extender (Extended Life Coolant Only) Cooling System - Drain/Clean/Replace Coolant - Conventional Coolant/Antifreeze Only Water Pump Seal - Inspect/Replace Hoses - Replace Thermostat - ReplaceEvery 90,000 L (24,000 gal) of Fuel or 4000 Service Hours*
Magnetic Pickup - Inspect/Clean SR4 Generator - Check/Inspect/Clean/LubricateEvery 135,000 L (36,000 gal) of fuel or 6,000 Service Hours or Four Years
Cooling System - Drain/Flush/Replace Coolant (Extended Life Coolant Only)*Perform previous maintenance interval items first.