Information injection-pump assembly
ZEXEL
101492-1020
1014921020
Rating:
Cross reference number
ZEXEL
101492-1020
1014921020
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4620
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.7
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
43.2
42.2
44.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
7.5
6.2
8.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.6+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60.5
60.5
65.5
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Setting at shipping
(4)Idle sub spring setting: L1.
----------
K=10 L1=6.7+-0.1mm
----------
----------
K=10 L1=6.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Set speed at bb (setting at shipping).
(3)Set the pump speed to cc.
(4)Stopper bolt setting
----------
aa=750r/min bb=950r/min cc=900r/min
----------
a=22deg+-5deg b=1deg+-5deg c=(2deg) d=6deg+-5deg
----------
aa=750r/min bb=950r/min cc=900r/min
----------
a=22deg+-5deg b=1deg+-5deg c=(2deg) d=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(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=16deg
----------
a=(130deg)
----------
aa=16deg
----------
a=(130deg)
Information:
3. Remove turbo supply and drain lines (1). 4. Remove bolts (3) that holds bonnet (2) to engine block and torque converter oil cooler.5. Remove bolts (5), (6) and (7) (not shown) and remove cooler. Install in the reverse order. Fill cooling system with coolant. See the Operation & Maintenance Manual for the proper procedure and levels. Check the engine oil level. See the Operation & Maintenance Manual for the proper procedure and levels.End By:a. install oil filters and baseDisassemble Engine Oil Cooler & Bypass Valves
Start By:a. remove engine oil cooler and bypass valves 1. Remove bolts (1) to remove bypass valve assembly (3) from oil cooler (2). 2. Remove adapter (6) from the engine oil cooler. Remove O-ring seals (5) from the adapter.3. Remove bolts (4) to remove cover (7). Remove valves (9) and springs (8) from water line.4. Remove tube (10) from water lines. Remove O-ring seals (11) from the tube. 5. Clean the engine oil cooler tubes with a 3.2 mm (.125 in) diameter rod as shown.Assemble Engine Oil Cooler & Bypass Valves
1. Install new O-ring seals (1) on adapter (2). Install adapter (2) in the engine oil cooler.2. Install new O-ring seals (7) on tube (6). Install tube in water lines.3. Install valves (5) and springs (4) in the water line. Install cover (3) with the bolts (9) that hold it. 4. Install the bypass valve assembly on the engine oil cooler with the bolts (8) that hold it. Install the cover and bolts (9).End By:a. install engine oil cooler and bypass valves
Start By:a. remove engine oil cooler and bypass valves 1. Remove bolts (1) to remove bypass valve assembly (3) from oil cooler (2). 2. Remove adapter (6) from the engine oil cooler. Remove O-ring seals (5) from the adapter.3. Remove bolts (4) to remove cover (7). Remove valves (9) and springs (8) from water line.4. Remove tube (10) from water lines. Remove O-ring seals (11) from the tube. 5. Clean the engine oil cooler tubes with a 3.2 mm (.125 in) diameter rod as shown.Assemble Engine Oil Cooler & Bypass Valves
1. Install new O-ring seals (1) on adapter (2). Install adapter (2) in the engine oil cooler.2. Install new O-ring seals (7) on tube (6). Install tube in water lines.3. Install valves (5) and springs (4) in the water line. Install cover (3) with the bolts (9) that hold it. 4. Install the bypass valve assembly on the engine oil cooler with the bolts (8) that hold it. Install the cover and bolts (9).End By:a. install engine oil cooler and bypass valves