101402-3951 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023951

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3951 1014023951

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Cross reference number

ZEXEL 101402-3951 1014023951

Zexel num

Bosch num

Firm num

Name

101402-3951

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 131424-3420

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 2.5 2.45 2.55

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 10

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 46 46

Boost pressure mmHg 345 345

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13 12 14

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 1200 1200 1200

Rack position R1-0.9

Boost pressure kPa 18.7 16 21.4

Boost pressure mmHg 140 120 160

Boost compensator adjustment_02

Pump speed r/min 1200 1200 1200

Rack position R1(10)

Boost pressure kPa 32.7 26 39.4

Boost pressure mmHg 245 195 295

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)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (When hydraulic cylinder is OFF) (5)Main spring setting (6)Set idle sub-spring (7)The torque control spring must does not have a set force. (8)Boost compensator stroke: BCL (9)When hydraulic cylinder ON: P1
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K=16 BCL=0.9+-0.1mm P1=((392)kPa,(4)kgf/cm2)
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the center hole at R = aa
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aa=80mm
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a=22deg+-3deg b=35deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
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aa=16deg bb=0deg
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a=54deg54min+-3deg b=8deg+-30min

Information:

Firing order (injection sequence) ... 1,8,4,3,6,5,7,2Injection timing before TC (top center): Precombustion Chamber (PC) ... 11 1°Direct Injection (DI) ... 28 1°(1) Torque for bushing ... 150 10 lb.ft.205 14 N m)(2) 1S7592 Lifter Spring: Length under test force ... 38.66 mm (1.522 in.)Test force ... 100 5 N (22.6 1.1 lb.)Free length after test ... 44.48 mm (1.751 in.)Outside diameter ... 25.27 mm (.995 in.)(2) 7N1208 Lifter Spring: Length under test force ... 29.26 mm (1.152 in.)Test Force ... 325 16 N (73.0 3.6 lb.)Free length after test ... 48.03 mm (1.891 in.)Outside diameter ... 25.27 mm (.995 in.)(3) 1S8634 Check Valve Spring for PC Engines: Length under test force ... 8.15 mm (.321 in.)Test force ... 0.85 0.04 N (.19 .01 lb.)Free length after test ... 10.77 mm (.424 in)Outside diameter ... 9.86 mm (.388 in.)(3) 6N24 Check Valve Spring for DI Engines: Length under test force ... 9.53 mm (.375 in.)Test force ... 56 3 N (12.5 .6 lb.)Free length after test ... 13.03 mm (.513 in.)Outside diameter ... 11.68 mm (.460 in.)(3) 8N1415 Spring For Reverse Flow Check Valve on Later DI Engines: Length under test force ... 8.69 mm (.342 in.)Test force ... 111 6 N (25 1 lb.)Free length after test ... 12.12 mm (.477 in.)Outside diameter ... 9.78 mm (.385 in.)(4) Thickness of spacers: 9N6496 Spacer ... 4.12 mm (.162 in.)9N6495 Spacer ... 4.22 mm (.166 in)5M2697 Spacer ... 4.32 mm (.170 in.)2M4208 Spacer ... 4.42 mm (.174 in.)2M4209 Spacer ... 4.52 mm (.178 in.)2M4210 Spacer ... 4.62 mm (.182 in.)2M4211 Spacer ... 4.72 mm (.186 in.)2M4212 Spacer ... 4.83 mm (.190 in.)5M2691 Spacer ... 4.93 mm (.194 in.)5S7189 Spacer ... 5.03 mm (.198 in.)(5) Bores for the racks: Bore in housing, at the rear (new) ... 12.758 0.038 mm (.5023 .0015 in.)Bearing at the front (new) ... 12.758 0.046 mm (.5023 .0018 in.)Diameter of fuel racks (new) ... 12.662 0.005 mm (.4985 .0002 in.)Maximum permissible clearance between rack and bearings (worn) ... 0.18 mm (.007 in.)(6) Bore in bearings for the camshaft (new) ... 53.988 0.038 mm (2.1255 .0005 in.) Diameter of bearing surfaces of the camshaft (new) ... 53.899 0.013 mm (2.1220 .0005 in.)Maximum permissible clearance between the bearings and the camshaft ... 0.25 mm (.010 in.)(7) Length of injection pump plunger. (8) Timing dimension for fuel injection pump. Use 6V7926 Indicator Group with 5P4158 Gauge (A) to measure this dimension.