101402-7091 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014027091

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-7091 1014027091

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Service parts 101402-7091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8311

3. GOVERNOR 105419-2880

4. SUPPLY PUMP 105220-6250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-8621

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6521

11. Nozzle and Holder 8-97030-285-1

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101402-7091 as INJECTION-PUMP ASSEMBLY

104302-1050 as _

Cross reference number

ZEXEL 101402-7091 1014027091

Zexel num

Bosch num

Firm num

Name

101402-7091

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 A

Rack position 8.8

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 83.5 82.4 84.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8.5 7.1 9.9

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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)Set idle sub-spring (4)Main spring setting
----------
K=12
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=18deg+-5deg b=30deg+-5deg c=35deg+-3deg

Stop lever angle

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

----------
a=4.5deg+-5deg b=53deg+-5deg

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=14deg
----------
a=(100deg)

Information:

LATER
EARLIERRemove Fuel Transfer Pump
1. Disconnect fuel lines (1) and (2) from the fuel transfer pump. Put plugs and caps in the openings. 2. Remove two bolts (3) that hold the fuel transfer pump to the fuel injection pump drive.3. Remove fuel transfer pump (4).Install Fuel Transfer Pump
1. Put fuel transfer pump (1) in position so the shaft is in alignment with the groove in the fuel injection pump drive. Install the bolts that hold it. 2. Remove the plugs or caps from the openings. Connect fuel lines (2) and (3) to the fuel transfer pump.3. Remove the air from the fuel system. See PRIMING THE FUEL SYSTEM in LUBRICATION AND MAINTENANCE GUIDE.Disassemble Fuel Transfer Pump (Earlier)
start by: a) remove fuel transfer pump 1. Remove six bolts (1) that hold the transfer pump cover to transfer pump body. Remove the cover.2. Remove the plug (2), seat, spring and fuel bypass valve from cover. 3. Remove the gear (5) and shaft assembly (4) from the body (3). 4. Remove the seals (6) from the body. 5. Use tooling (A) to remove the bearing from the body.Assemble Fuel Transfer Pump (Earlier)
1. Use tooling (A) to install bearing into body.2. Use tool (B) to install inner seal in body. Install seal with lip of seal in the direction of the gears. 3. Use tool (C) to install outer seal in the body. Install seal with lip of seal toward the outside. 4. Install tool (D) on to shaft assembly (1) and install shaft assembly into body.
Tool (D) must be used to install shaft assembly. The shaft will cause damage to seals if it is not used.
5. Install idler gear (2) in the body. 6. Install fuel bypass valve (3), spring (4), seat (5), and plug into cover.7. Put a thin amount of 8S6747 Aviation Type Permatex on face of body.
Do not let Permatex get into the pump body.
8. Put the cover (6) in position on the body and install the six bolts. After tightening cover to body, the gear and shaft assembly must turn freely.end by: a) install fuel transfer pump