101491-9781 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919781

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101491-9781 1014919781

Service parts 101491-9781 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9720

3. GOVERNOR 105400-7230

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-0780

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5230

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105048-3680

14. NOZZLE

105017-0700

15. NOZZLE SET

Include in #1:

101491-9781 as INJECTION-PUMP ASSEMBLY

106691-4020 as _

Cross reference number

ZEXEL 101491-9781 1014919781

Zexel num

Bosch num

Firm num

Name

101491-9781

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 131424-6220

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 3.6 3.55 3.65

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 11

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 37.7 36.7 38.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 10.5+-0. 5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.6 8.6 10.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 1200++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1200.

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)The torque control spring must does not have a set force. (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
----------
K=6 N1=1200r/min N2=800r/min N3=1200r/min N4=300r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=5deg+-5deg b=27deg+-5deg

Stop lever angle

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

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

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