Information injection-pump assembly
ZEXEL
101402-7200
1014027200
Rating:
Service parts 101402-7200 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97079-653-0
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Include in #1:
101402-7200
as INJECTION-PUMP ASSEMBLY
Include in #2:
104206-1051
as _
Cross reference number
ZEXEL
101402-7200
1014027200
Zexel num
Bosch num
Firm num
Name
101402-7200
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-0820
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
2.25
2.2
2.3
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.2
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
40.4
39.4
41.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
17.3
15.3
19.3
Max. variation between cylinders
%
0
-15
15
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=18
----------
----------
K=18
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=12deg+-5deg
----------
----------
a=10deg+-5deg b=12deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'W' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(210deg)
----------
aa=14deg
----------
a=(210deg)
Information:
1. Remove bolt (1) from the alternator and bracket. 2. Remove the two bolts that hold bracket (3) to the timing gear cover.3. Disconnect water line (2) from the air compressor. 4. Remove bolts (4) and (5) that hold the cylinder head to the cylinder block. 5. Fasten a hoist and remove cylinder head (6). The weight is approximately 300 lb. (135 kg).
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
6. Remove the seals from the spacer plate.Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See REMOVE AND INSTALL SPACER PLATE. 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head. Install a new head gasket and new seals (1). Later model engines have two O-ring seals on top and bottom of the spacer plate. 2. Fasten a hoist and put cylinder head (2) in position on the cylinder block. 3. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown in illustration A87019x1: a) Tighten bolts 1 through 20 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (450 20 N m).c) Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (450 20 N m) by hand.d) Install rocker shafts and push rods. See INSTALL ROCKER SHAFTS AND PUSH RODS.e) Tighten bolts 21 through 26 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).f) Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (450 20 N m).g) Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (450 20 N m) by hand.h) Tighten the 3/8" bolts to a torque of 32 5 lb. ft. (43 7 N m). If the studs for the exhaust manifold were removed, install new studs and tighten to 20 3 lb.ft. (25 4 N m).4. Make a adjustment to the valves to have a clearance of .015 (0.38 mm) for intake and .030 (0.76 mm) for exhaust. Install the valve cover bases and the inner fuel lines. Tighten the locknuts for the valve adjustment screws to a torque of 22 3 lb.ft. (28 4 N m).5. Install the valve cover bases and the inner fuel lines. See INSTALL ROCKER SHAFT AND PUSH RODS.6. Install the valve covers. See INSTALL VALVE COVERS. 7. Connect water line (3) to the air compressor. 8. Install bolt (4) for the alternator.end by:a) install exhaust manifoldb) install fuel injection linesc) install inlet manifoldd) install water temperature regulator
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
6. Remove the seals from the spacer plate.Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See REMOVE AND INSTALL SPACER PLATE. 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head. Install a new head gasket and new seals (1). Later model engines have two O-ring seals on top and bottom of the spacer plate. 2. Fasten a hoist and put cylinder head (2) in position on the cylinder block. 3. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown in illustration A87019x1: a) Tighten bolts 1 through 20 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (450 20 N m).c) Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (450 20 N m) by hand.d) Install rocker shafts and push rods. See INSTALL ROCKER SHAFTS AND PUSH RODS.e) Tighten bolts 21 through 26 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).f) Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (450 20 N m).g) Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (450 20 N m) by hand.h) Tighten the 3/8" bolts to a torque of 32 5 lb. ft. (43 7 N m). If the studs for the exhaust manifold were removed, install new studs and tighten to 20 3 lb.ft. (25 4 N m).4. Make a adjustment to the valves to have a clearance of .015 (0.38 mm) for intake and .030 (0.76 mm) for exhaust. Install the valve cover bases and the inner fuel lines. Tighten the locknuts for the valve adjustment screws to a torque of 22 3 lb.ft. (28 4 N m).5. Install the valve cover bases and the inner fuel lines. See INSTALL ROCKER SHAFT AND PUSH RODS.6. Install the valve covers. See INSTALL VALVE COVERS. 7. Connect water line (3) to the air compressor. 8. Install bolt (4) for the alternator.end by:a) install exhaust manifoldb) install fuel injection linesc) install inlet manifoldd) install water temperature regulator
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101402-7200
INJECTION-PUMP ASSEMBLY