101401-2080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012080

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101401-2080 1014012080

Service parts 101401-2080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9252

3. GOVERNOR 105921-2090

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0230

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5050

11. Nozzle and Holder 23600-1880

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-7280

15. NOZZLE SET

Include in #1:

101401-2080 as INJECTION-PUMP ASSEMBLY

108622-3473 as _

108622-3475

108622-3476

Cross reference number

ZEXEL 101401-2080 1014012080

Zexel num

Bosch num

Firm num

Name

101401-2080

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.2 3.17 3.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 10.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 84.2 82.2 86.2

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.6 7.1 10.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 84.2 83.2 85.2

Basic *

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 86.2 82.2 90.2

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 85.2 81.2 89.2

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 65.2 61.2 69.2

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_07

Adjusting point E

Rack position -

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 49.6 45.6 53.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_08

Adjusting point I

Rack position 14.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 106 106 116

Fixing the lever *

Rack limit *

Injection quantity adjustment_09

Adjusting point K

Rack position R1-1.1

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 51.9 47.9 55.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-1.1

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1-0.5

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

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)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=C29 BCL=0.6+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=34deg+-5deg b=43deg+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (After setting, apply red paint.)
----------

----------
a=20deg+-5deg b=(28deg)+-5deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1600r/min Ra=0.4mm Rb=R1(10.8)mm Rc=R1(10.8)mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)

0000001601 ACTUATOR

(a) Screw (B) Nut (c) set bolt (d) control lever 1. Actuator adjustment procedure (1)Position the control lever (d) in the idling position. (2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator. (5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0. (7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=9.1~9.4mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
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Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)