101405-3251 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014053251

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101405-3251 1014053251

Service parts 101405-3251 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9581

3. GOVERNOR 105404-5830

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105158-5012

11. Nozzle and Holder 4063269

12. Open Pre:MPa(Kqf/cm2) 22.0{224}

13. NOZZLE-HOLDER 105088-2002

14. NOZZLE

105017-2910

15. NOZZLE SET

Include in #1:

101405-3251 as INJECTION-PUMP ASSEMBLY

101609-9221 as _

Cross reference number

ZEXEL 101405-3251 1014053251

Zexel num

Bosch num

Firm num

Name

101405-3251

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 131424-3420

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 2.5 2.45 2.55

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 9.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 103 102 104

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 420 420 420

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 8.55

Boost pressure kPa 12 9.3 14.7

Boost pressure mmHg 90 70 110

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position 10.35

Boost pressure kPa 40 40 40

Boost pressure mmHg 300 300 300

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)When the hydraulic cylinder is OFF (4)Boost compensator stroke: BCL (5)When hydraulic cylinder ON: P1 (6)Rack difference between N = N1 and N = N2 (7)Adjust the secondary timing before adjusting the governor.
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K=12 BCL=1.8+-0.1mm P1=(127+-10kPa,{1.3+-0.1kgf/cm2}) N1=1100r/min N2=650r/min
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=60mm
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a=18deg+-5deg b=35deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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a=0deg+-5deg b=53deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure After adjusting the boost compensator (A) (B), tighten the bolts to remove the heads. (1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2 maximum)
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T1=2.9~4.9N-m(0.3~0.5kgf-m) T2=2.5N-m(0.25kgf-m)
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Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
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aa=13deg bb=0deg
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a=54deg54min+-3deg b=6deg30min+-30min