101491-9701 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data


Information injection-pump assembly

ZEXEL 101491-9701 1014919701

Service parts 101491-9701 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-9531
3. GOVERNOR 105921-3650
4. SUPPLY PUMP
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 SL0113640A
12. Open Pre:MPa(Kqf/cm2) 16.7(170)
13. NOZZLE-HOLDER 105048-3050
14. NOZZLE 105017-0070
15. NOZZLE SET

Include in #1:

101491-9701 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-9701 1014919701


Zexel num Bosch num Firm num Firm Name
101491-9701        INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-3-4-2
Pre-stroke mm   3.4 3.35 3.45
Beginning of injection position   NO.1
Drive side
Difference between angles 1 deg.   90 89.5 90.5
Cal 1-3
Difference between angles 2 deg.   180 179.5 180.5
Cal 1-4
Difference between angles 3 deg.   270 269.5 270.5
Cyl.1-2


Injection quantity adjustment
Adjusting point   -
Rack position   10.9
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   50.6 50.1 51.1
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   R1(10.9)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   50.6 50.1 51.1
Basic   *
Fixing the lever   *


Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.3
Pump speed r/min   1700 1700 1700
Average injection quantity mm3/st.   61 57 65
Fixing the lever   *


Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.13
Pump speed r/min   625 625 625
Average injection quantity mm3/st.   39 35 43
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 101491-9701 N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=C83
----------



Speed control lever angle

Test data 101491-9701 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 101491-9701 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 LEVER

Test data 101491-9701 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
----------



Timing setting

Test data 101491-9701 (1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)





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