101402-7101 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014027101

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-7101 1014027101

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Service parts 101402-7101 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8440

3. GOVERNOR 105419-2551

4. SUPPLY PUMP 105220-6250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-8420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4480

11. Nozzle and Holder 8-97134-842-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101402-7101 as INJECTION-PUMP ASSEMBLY

Include in #2:

104278-4231 as _

Cross reference number

ZEXEL 101402-7101 1014027101

Zexel num

Bosch num

Firm num

Name

101402-7101

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 3.2 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 A

Rack position 9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 90.5 89.4 91.6

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 6.6 9.4

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=7
----------

Speed control lever angle

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

----------
a=25deg+-5deg b=6deg+-5deg

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=12deg
----------
a=(100deg)

Information:

Remove Fuel Ratio Control
1. Disconnect line (1) from the fuel ratio control.2. Remove the wire seal from the bolts.3. Remove two bolts (2). Remove fuel ratio control (3) after it is moved down and out from the collar.Install Fuel Ratio Control
1. Put the fuel ratio control on the governor. 2. Be sure bolt (2) of the fuel ratio control is connected in the groove of collar (1).3. Install the two bolts that hold the fuel ratio control on the governor.4. Connect the line to the fuel ratio control.5. Install a wire seal on the bolts.Disassemble Fuel Ratio Control
start by:a) remove fuel ratio control 1. Remove the bolts and the housing (1).2. Remove wire seal (2) from the bolts. 3. Remove valve assembly (3).4. Remove seal (4) and O-ring seal from valve.5. Remove the retainer (5) and two springs (6). 6. Remove three bolts (9) and cover (10).7. Remove valve (7), diaphragm (8), retainer and spring. 8. Remove pin (12) from valve (7).9. Remove cover (11) from the valve.10. Remove the seal from the cover (11).Assemble Fuel Ratio Control
1. Put clean engine oil on lip of seal. Install the seal (1) in cover (2). Install seal so lip of seal is toward the inside of the cover. 2. Install the valve (3) into cover (2).3. Install the pin that holds cover on valve. 4. Install spring (7) and the retainer (6) in cover (8).5. Install diaphragm (5) on the valve assembly (4) and in the cover. 6. Install cover and three bolts (11) that hold covers together. Install wire seal on the bolts with tool group (A) after the fuel ratio control is installed and adjustments are made to it.7. Put clean engine oil on seal and ring seal. Install the seals (1) on valve.8. Install the two springs (13), retainer, and valve assembly (12).9. Install housing (9) and two bolts.end by: a) install fuel ratio control