Information injection-pump assembly
ZEXEL
101492-1030
1014921030

Rating:
Cross reference number
ZEXEL
101492-1030
1014921030
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)At shipping
(3)Set the pump speed at bb.
(4)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=22deg+-5deg b=1deg+-5deg c=(2deg) d=6deg+-5deg
----------
aa=750r/min bb=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:
1. Remove turbocharger return oil line (1).2. Remove two shields (2) from exhaust manifold (3). 3. Remove clamp (4).4. Remove nuts, spacers and brackets (5).5. Remove exhaust manifold (3).6. Remove the gaskets from the exhaust manifold or studs. 7. Separate section (6), sections (7) and section (8).Install Exhaust Manifold
Make sure the 2P-2333 Manifold Sealer does not get on the inside of each manifold. Damage to the turbocharger could be the result if the manifold sealer gets on the impeller on the turbocharger.
1. Apply a thin coat of 2P-2333 Manifold Sealer to the O.D. of male end of the manifold sections (7) and section (8). Coat the female ends of the manifold with clean engine oil.2. Connect sections (6), sections (7) and section (8). 3. Install 5P-3931 Anti-Seize Compound on the threads of studs (9).4. Install the gaskets on the studs. 5. Install exhaust manifold (3).6. Install nuts, spacers and brackets (5). Tighten the nuts to a torque of 38 5 N m (28 4 lb ft).7. Install clamp (4). 8. Install two shields (2) to exhaust manifold (3).9. Using a new O-ring seal at the bottom and a new gasket at the top, install turbocharger return oil line (1).
Make sure the 2P-2333 Manifold Sealer does not get on the inside of each manifold. Damage to the turbocharger could be the result if the manifold sealer gets on the impeller on the turbocharger.
1. Apply a thin coat of 2P-2333 Manifold Sealer to the O.D. of male end of the manifold sections (7) and section (8). Coat the female ends of the manifold with clean engine oil.2. Connect sections (6), sections (7) and section (8). 3. Install 5P-3931 Anti-Seize Compound on the threads of studs (9).4. Install the gaskets on the studs. 5. Install exhaust manifold (3).6. Install nuts, spacers and brackets (5). Tighten the nuts to a torque of 38 5 N m (28 4 lb ft).7. Install clamp (4). 8. Install two shields (2) to exhaust manifold (3).9. Using a new O-ring seal at the bottom and a new gasket at the top, install turbocharger return oil line (1).