101491-9651 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919651

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9651 1014919651

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Service parts 101491-9651 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9531

3. GOVERNOR 105921-3730

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:

101491-9651 as INJECTION-PUMP ASSEMBLY

106671-4550 as _

Cross reference number

ZEXEL 101491-9651 1014919651

Zexel num

Bosch num

Firm num

Name

101491-9651

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 -

Rack position 9.6+-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 *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

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 15++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 106 96 116

Fixing the lever *

Injection quantity adjustment_07

Adjusting point H

Rack position 9.3+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 7 6.5 7.5

Fixing the lever *

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 4

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)Torque cam set point
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.3)mm bb=325r/min
----------
a=20deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Engine stop (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(30deg)+-5deg

0000001501 LEVER

CL:Center line of camshaft ST:Stop adjuster screw f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever 1. Stop lever adjustment outline (1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position. (2)Set the speed lever in the full speed position. (3)At pump speed Na, position the rack at non-injection position Ra. (4)Set the stop adjusting screw to fix the speed lever in the idling position. (5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=4.6+-0.3mm
----------

0000001601 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)
----------

----------
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

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:

start by:a) remove fuel injection lines**This operation location is in the ENGINE DISASSEMBLY AND ASSEMBLY section. 1. Disconnect the fuel lines from fuel transfer pump (4) and fuel manifold (3). Disconnect fuel line (2) from the fitting. Disconnect the fuel return line to the tank at (1). Install plugs or caps on all fuel line openings.2. Disconnect drain line (5) from the governor housing. Move the fuel lines and drain line clear of the fuel injection pump housing and governor. 3. Remove bolts (6) that hold the oil manifold to the governor housing. 4. Remove cover (7) from the timing gear cover.5. Remove the bolt and washer that hold the timing gear to the camshaft in the fuel injection pump housing. 6. Install tooling (A) and loosen the timing gear on the camshaft in the fuel injection pump housing.7. Fasten a strap and hoist to the fuel injection pump housing and governor as shown. 8. Remove three nuts (8) and remove the fuel injection pump housing and governor. Weight is 25 kg (56 lb.).Install Fuel Injection Pump Housing And Governor
1. Be sure O-ring seals (1) and (2) are in position on the fuel injection pump housing and governor and put clean oil on the O-ring seals.2. Remove the cover on the fuel injection pump housing and install timing pin (A). Turn the camshaft until timing pin (A) goes in the groove in the camshaft as shown. 3. Fasten a strap and hoist to the fuel injection pump housing and governor and put in position on the timing gear plate and oil manifold (3). Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to oil manifold (3).
After the fuel injection pump housing and governor are installed on the timing gear plate be sure the rack is free to move. The O-ring seal on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install the bolt and washer (4) as shown to hold the timing gear to the camshaft. Install washer (4) with the larger outside diameter toward the bolt head. Tighten the bolt finger tight only.5. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given. Do not turn the flywheel backward. a) Remove plug (5) from the flywheel housing and the breather from the valve cover.b) Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (6) at least 2.5 in. long can be installed in the flywheel through the hole in