101491-9730 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919730

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101491-9730 1014919730

Service parts 101491-9730 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9440

3. GOVERNOR 105921-3000

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:

101491-9730 as INJECTION-PUMP ASSEMBLY

106692-4103 as _

Cross reference number

ZEXEL 101491-9730 1014919730

Zexel num

Bosch num

Firm num

Name

101491-9730

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 *

Remarks
Set lever at delivery.

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

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

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

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

0000001501 GOV RACK POSITION CONFIRM

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

Timing setting

(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=13deg
----------
a=(130deg)