101302-9003 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1013029003

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101302-9003 1013029003

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Cross reference number

ZEXEL 101302-9003 1013029003

Zexel num

Bosch num

Firm num

Name

101302-9003

DPICO

INJECTION-PUMP ASSEMBLY
3D100-AT * Q

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 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 1-3-2

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 2
Cyl.1-2 deg. 240 239.5 240.5

Injection quantity adjustment

Adjusting point A

Rack position 9.5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 46.2 45.2 47.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Torque spring does not operate.
----------
K=10
----------

Speed control lever angle

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

----------
a=(14deg)+-5deg b=(34deg)+-5deg

Stop lever angle

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

----------
a=15deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'B' at the No 3 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=17deg
----------
a=(100deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new 563-5865 Solenoid As replaces the previous solenoid assembly. The 563-5865 Solenoid As is not a serviceable part. The fuel injector has to be replaced as the serviceable component.