101491-9750 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919750 slk113800


101491-9750 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101491-9750 1014919750
MAZDA SLK113800 slk113800

Service parts 101491-9750 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-9480
3. GOVERNOR 105921-3280
4. SUPPLY PUMP 105220-5252
5. AUTOM. ADVANCE MECHANIS 105670-0380
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-4252
11. Nozzle and Holder SL50 13 H50A
12. Open Pre:MPa(Kqf/cm2) 16.7{170}
13. NOZZLE-HOLDER 105048-3121
14. NOZZLE 105017-0211
15. NOZZLE SET

Include in #1:

101491-9750 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-9750 1014919750
MAZDA SLK113800 slk113800


Zexel num
Bosch num
Firm num
Name
101491-9750 
101491-9751 
 
SLK113800  MAZDA
INJECTION-PUMP ASSEMBLY
SL-T * K

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   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   3.2 3.15 3.25
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   12.77+-0 .02
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   73.2 72.7 73.7
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   10.1+-0. 5
Pump speed r/min   340 340 340
Average injection quantity mm3/st.   10 8 12
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   12.77+-0 .5
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   73.2 72.7 73.7
Basic   *
Fixing the lever   *
Boost pressure kPa   21.3 21.3
Boost pressure mmHg   160 160
Injection quantity adjustment_04
Adjusting point   B
Rack position   12.91+-0 .5
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   83.7 81.7 85.7
Fixing the lever   *
Boost pressure kPa   21.3 21.3
Boost pressure mmHg   160 160
Injection quantity adjustment_05
Adjusting point   C
Rack position   11.97+-0 .5
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   49.3 47.3 51.3
Fixing the lever   *
Boost pressure kPa   21.3 21.3
Boost pressure mmHg   160 160
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   75 70 85
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   10.49+-0 .05
Boost pressure kPa   2 2 4.7
Boost pressure mmHg   15 15 35
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   11.69+-0 .02
Boost pressure kPa   12 9.3 14.7
Boost pressure mmHg   90 70 110
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   2.3 1.8 2.8
Timer adjustment_04
Pump speed r/min   (1600)
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101491-9750
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: R1, speed N1 (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=C60 R1=+-0.02mm N1=+-3r/min BCL=1.2+-0.1mm
----------

Speed control lever angle

Test data 101491-9750
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=36mm
----------
a=20deg+-5deg b=43deg+-3deg

Stop lever angle

Test data 101491-9750
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(29deg)+-5deg

0000001501 GOV RACK POSITION CONFIRM

Test data 101491-9750
Confirm the governor adjustment rack position. (N): Speed of the pump (R) Rack position (mm) Standard point A (B) Confirmation Remarks C
----------

----------
Na=1000r/min Nb=625r/min Nc=1700r/min Nd=1500r/min Ne=1250r/min Nf=400r/min Ra=12.77+-0.02mm Rb=11.69+-0.02mm Rc=12.84+-0.05mm Rd=13.04+-0.05mm Re=13.23+-0.05mm Rf=12.15+-0.05mm

0000001601 LEVER

Test data 101491-9750
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=340r/min Ra=5.1+-0.3mm
----------

Timing setting

Test data 101491-9750
(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=11deg
----------
a=(130deg)




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