101491-9591 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919591


101491-9591 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101491-9591 1014919591

Service parts 101491-9591 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-9531
3. GOVERNOR 105921-3550
4. SUPPLY PUMP 105220-5252
5. AUTOM. ADVANCE MECHANIS 105670-0080
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-4091
11. Nozzle and Holder SL01 13 640A
12. Open Pre:MPa(Kqf/cm2) 16.7{170}
13. NOZZLE-HOLDER 105048-3121
14. NOZZLE 105017-2070
15. NOZZLE SET

Include in #1:

101491-9591 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-9591 1014919591


Zexel num
Bosch num
Firm num
Name
101491-9591 
 
   
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 opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.4 3.35 3.45
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   -
Rack position   11.21+-0 .02
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   56.8 56.3 57.3
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.6+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   9 7 11
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   11.21+-0 .5
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   56.8 56.3 57.3
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   11.48+-0 .5
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   68.9 66.9 70.9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   11.32+-0 .5
Pump speed r/min   625 625 625
Average injection quantity mm3/st.   42 40 44
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   16.3+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   91 81 96
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_07
Adjusting point   H
Rack position   9.3+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   7 6.5 7.5
Fixing the lever   *
Timer adjustment
Pump speed r/min   1350+-25
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1700
Advance angle deg.   3.5 3.2 3.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101491-9591
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: R1, speed N1 (3)RACK LIMIT
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------

Speed control lever angle

Test data 101491-9591
F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Rack position = aa, speed = bb
----------
aa=(9.3)mm bb=325r/min
----------
a=20deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101491-9591
N:Pump normal S:Engine stop (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(30deg)+-5deg

0000001501 GOV RACK POSITION CONFIRM

Test data 101491-9591
Confirm the governor adjustment rack position. Standard point A Set the torque cam B. (C) Confirmation (D) Remarks (N): Speed of the pump (R) Rack position (mm)
----------

----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.21+-0.02mm Rb=11.32+-0.02mm Rc=11.27+-0.1mm Rd=11.48+-0.05mm Re=11.39+-0.05mm Rf=11.46+-0.05mm

0000001601 LEVER

Test data 101491-9591
CL:Center line of camshaft ST:Stop adjuster screw f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever 1. Stop lever adjustment outline (1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position. (2)Set the speed lever in the full speed position. (3)At pump speed Na, position the rack at non-injection position Ra. (4)Set the stop adjusting screw to fix the speed lever in the idling position. (5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=4.6+-0.3mm
----------

0000001701 ACS

Test data 101491-9591
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=(11.21)mm Rb=(10.8)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=56.8+-0.5cm3/1000st Q2=48.8+-1cm3/1000st

Timing setting

Test data 101491-9591
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(130deg)




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