101491-9781 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919781


 

Information injection-pump assembly

ZEXEL 101491-9781 1014919781
101491-9781 INJECTION-PUMP ASSEMBLY
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Service parts 101491-9781 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-9720
3. GOVERNOR 105400-7230
4. SUPPLY PUMP 105220-5150
5. AUTOM. ADVANCE MECHANIS 105676-0780
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5230
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105048-3680
14. NOZZLE 105017-0700
15. NOZZLE SET

Include in #1:

101491-9781 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-9781 1014919781


Zexel num
Bosch num
Firm num
Name
101491-9781 
 
   
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   131424-6220
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.6 3.55 3.65
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   A
Rack position   11
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   37.7 36.7 38.7
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   10.5+-0. 5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   9.6 8.6 10.6
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Timer adjustment
Pump speed r/min   1200++
Advance angle deg.   0 0 0
Remarks
Do not advance until starting N = 1200.
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   3 3 3
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101491-9781
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)The torque control spring must does not have a set force. (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
----------
K=6 N1=1200r/min N2=800r/min N3=1200r/min N4=300r/min
----------

Speed control lever angle

Test data 101491-9781
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=5deg+-5deg b=27deg+-5deg

Stop lever angle

Test data 101491-9781
N:Pump normal S:Stop the pump.
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

Test data 101491-9781
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)




Information:


When using an external electrical source to start your engine: turn the START switch off, remove the key, and turn off all electrical accessories before attaching cables.When using jumper cables always connect the POSITIVE (+) cable to the POSITIVE (+) terminal of the battery connected to the starter solenoid. Connect the NEGATIVE (-) cable from the external source to the starter NEGATIVE (-) terminal. If not equipped with a starter NEGATIVE terminal, connect to the engine block.Do not reverse the battery cables. The alternator can be damaged. Attach the ground cable last and remove first.
1. Connect one end of the cable to the POSITIVE (+) terminal of the battery being started. Connect the other end to the POSITIVE (+) terminal of the power source.2. Connect one of the other cable to the NEGATIVE (-) terminal of the power source. Connect the other end to starter NEGATIVE (-) terminal or to the engine block. This prevents potential sparks from igniting combustible gases produced by some batteries.3. Start the engine.4. After the engine starts, disconnect the cable from the starter NEGATIVE (-) terminal or engine block. Disconnect the other end from the NEGATIVE (-) terminal of the power source.5. Disconnect the cable from the POSITIVE (+) terminal of the battery on the engine being started. Disconnect the cable from the POSITIVE (+) terminal of the power source.Air Starting
For good life of the air starting motor, the air supply must be free of dirt and water. A lubricator must be used with the starting system. Use non detergent 10W engine oil for temperatures that are greater than 0°C (32°F) or use air tool oil for lower temperatures.1. Open and close the drain valve on the bottom of the air tank to drain condensation and oil carryover.2. Check the air supply pressure. The air starting motor requires a minimum of 690 kPa (100 psi) air pressure to operate properly. The maximum air pressure must not exceed 1550 kPa (225 psi). The normal air pressure will be 758 to 965 kPa (110 to 140 psi).
Air Starter showing Air Valve (1) and Lubricator Bowl (2)3. Check the oil level in the lubricator bowl (2). Keep the bowl at least half full and add lubricant if necessary.4. Push the air valve (1) or the engine start button to crank the engine. Release the valve or button as soon as the engine starts.Cold Weather Starting Aids
Personal injury or death can result from using ether.Personal injury or property damage can result from alcohol or starting fluids. Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property damage.When using starting fluid, follow the manufacturer's instructions carefully. Use ether sparingly and spray it only while cranking the engine.Failure to follow these instructions could result in an explosion and/or fire and possible personal injury.
Excessive ether can cause piston and ring damage. Use ether for cold starting purposes only. Do not use excessive starting fluid during starting or after the engine is

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Group cross 101491-9781 ZEXEL

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Mazda 

 
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Hyundai 

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