101405-3251 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014053251


101405-3251 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101405-3251
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.
----------
K=12 BCL=1.8+-0.1mm P1=(127+-10kPa,{1.3+-0.1kgf/cm2}) N1=1100r/min N2=650r/min
----------

Speed control lever angle

Test data 101405-3251
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=60mm
----------
a=18deg+-5deg b=35deg+-5deg

Stop lever angle

Test data 101405-3251
N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

0000001501 TAMPER PROOF

Test data 101405-3251
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)
----------
T1=2.9~4.9N-m(0.3~0.5kgf-m) T2=2.5N-m(0.25kgf-m)
----------

Timing setting

Test data 101405-3251
(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.
----------
aa=13deg bb=0deg
----------
a=54deg54min+-3deg b=6deg30min+-30min




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