101402-7350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014027350

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-7350 1014027350

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Service parts 101402-7350 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8430

3. GOVERNOR 105419-3160

4. SUPPLY PUMP 105220-6250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-8420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4170

11. Nozzle and Holder 1-15300-331-0

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

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101402-7350 as INJECTION-PUMP ASSEMBLY

101601-1780 as _

101601-6000

Cross reference number

ZEXEL 101402-7350 1014027350

Zexel num

Bosch num

Firm num

Name

101402-7350

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 8.7

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 87 85.9 88.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.2+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8.8 7.4 10.2

Max. variation between cylinders % 0 -14 14

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)Set idle sub-spring (4)Main spring setting
----------
K=10
----------

Speed control lever angle

F:Full speed I:Idle D:Dead point (1)With variable lever
----------

----------
a=(21deg)+-5deg b=(19deg)+-5deg c=(10deg)+-3deg

Stop lever angle

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

----------
a=6deg+-5deg b=46deg+-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:

Cylinder Head Removal And Installation
Refer to SERVICE GUIDE for Preliminary Information.
1-Water pipe. 2-Fan and pulley mounting bracket assembly. 3-Water bypass line. 4-Air compressor water return line.
5-Turbocharger-to-inlet manifold air pipe. 6-Turbocharger lubrication oil supply line. 7-Turbocharger oil drain line. 8-Exhaust elbow. 9-Turbocharger. 10-Fuel lines (six). 11-Valve cover. 12-Cylinder head.Cylinder Head Disassembly And Assembly
Refer to SERVICE GUIDE for Preliminary Information.5F8353 Wrench5S1330 Valve Spring Compressor Group7S8858 Valve Guide Driver Bushing7S8859 Valve Guide DriverFT192 Driver9M3710 Anti-Seize Compound8S3080 Tool Group9S3084 Extractor Head9S3087 Extractor HeadApply 9M3710 Anti-Seize Compound to threads. Tighten all head bolts (1, 2 and 3) in Step sequence shown. Use gaskets (6) to position precombustion chambers (4) to prevent wiring interference. Install thinnest gasket (6) first. Install precombustion chamber and tighten to specified torque. If the glow plug opening is not positioned in the "go" range, remove the chamber and replace gasket with that called for in the diagram.4 Use 5F8353 Wrench to remove and install chamber. Coat threads with 9M3710 Anti-Seize Compound.5 Coat seal and mating surface in bore with liquid soap.7 Align opening in water director with "V" mark on head.8 Gasket to be clean and dry at installation.9, 10 Tool required: 5S1330 Valve Spring Compressor Group. Assemble spring with painted end up.11 Tool required to remove valve guide: 7S8859 Valve Guide Driver. Tools required to install valve guide: 7S8859 Valve Guide Driver, 7S8858 Valve Guide Driver Bushing.12 Valve seat inserts can be removed and new inserts installed in the cylinder heads. Tools required to remove inserts: 9S3080 Tool Group, 9S3084 Extractor Head, 9S3087 Extractor Head.13 Tool required to install bearing: FT192 Driver. Align hole in bearing with hole in rocker arm.