101491-9701 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919701

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9701 1014919701

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Service parts 101491-9701 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9531

3. GOVERNOR 105921-3650

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 105048-3050

14. NOZZLE

105017-0070

15. NOZZLE SET

Include in #1:

101491-9701 as INJECTION-PUMP ASSEMBLY

106692-4423 as _

Cross reference number

ZEXEL 101491-9701 1014919701

Zexel num

Bosch num

Firm num

Name

101491-9701

INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE

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 10.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 50.6 50.1 51.1

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 R1(10.9)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 50.6 50.1 51.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 61 57 65

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.13

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 39 35 43

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 *

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 3.2 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: +-0.05mm. (3)RACK LIMIT
----------
T1=C83
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)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
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)

Information:

a) Remove by screwing flywheel attaching bolts uniformly into the bolt holes for removal. Pull out using the special tool, Gear Puller. Do not remove the gear by striking it. b) Heat the gear to about 100°C by a heater, etc. Aligning the crankshaft dowel pin with the dowel pin hole in the gear, insert the shaft into the gear, lightly striking the gear end face with a soft hammer.c) Install the sleeve using the special tool, Oil Seal and Sleeve Installer. [Refer to Item (2) - (b), Section 5.1.3.](3) Reassembly Reassembly
(a) Installation of oil jet (excluding 6D14, 6D15) Fix the oil jet aligning with the locating pin and tighten the check valve to specified torque. Bend lock washer onto the check valve to prevent it from turning.(b) Installation of thrust plate and main bearing 1. Install the thrust plate with its side having no oil groove toward the crankcase.2. Line up the lug of main bearing with the lug groove in crankcase. Note that the upper main bearing has an oil hole, which must not be confused with the lower bearing.3. Apply engine oil to all sliding surfaces.(c) Installation of main bearing cap 1) Fit the lower main bearing into the main bearing cap. At the time, make sure that the main bearing lug is aligned with the main bearing cap lug groove.2) Install also the thrust plate onto the main bearing cap in the rear-end position.3) Make sure that the main bearing cap lug groove and crankcase lug groove are on the same side. 1. Face the side of thrust plate having no oil groove toward the rear end of the crankcase and toward the main bearing cap.2. Use thrust plates of the same size for the rear end of the crankcase and main bearing cap rear end. 4) Tighten the main bearing cap bolt to specification. Then, make sure that the crankshaft turns smoothly by hand.5) Measure the crankshaft end play to determine if it is within the nominal value [Refer to Item (1) - (c), Section 5.1.4.].(d) Reassembly of piston and connecting rod 1) Assemble the piston and the connecting rod, ensuring correct direction as illustrated.2) Insert the piston pin to couple the piston and connecting rod. Mount the snap ring to hold the piston pin in position. The piston pin is a clearance fit in the piston. If the piston pin is hard to fit, heat the piston with a piston heater or hot water. 1. Keep the piston weight difference for one engine within 10 g.2. Use connecting rod assembly of same weight mark for an engine.3. Check to see that the size mark of the piston is same as that of the cylinder liner.4. Apply engine oil to sliding surfaces. 3) The connecting rod bolts do not normally need removal; however, where replacement is necessary for damaged bolt, install new bolts by using the following procedures. Make sure that the connecting rod bolt hole is free from damage and burrs. Then,