Information injection-pump assembly
ZEXEL
101402-9363
1014029363
Rating:
Cross reference number
ZEXEL
101402-9363
1014029363
Zexel num
Bosch num
Firm num
Name
101402-9363
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
131424-1520
Overflow valve opening pressure
kPa
157
157
157
Overflow valve opening pressure
kgf/cm2
1.6
1.6
1.6
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.6
3.55
3.65
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
8
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
31.2
30.2
32.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.5+-0.5
Pump speed
r/min
415
415
415
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
9.8++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
60
70
Fixing the lever
*
Rack limit
*
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)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference between N = N1 and N = N2
----------
K=10 N1=1225r/min N2=480r/min
----------
----------
K=10 N1=1225r/min N2=480r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(28deg)+-5deg b=(13deg)+-5deg
----------
----------
a=(28deg)+-5deg b=(13deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=7deg+-5deg b=53deg+-5deg
----------
----------
a=7deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove idler gear (7).2. Remove the gear train housing, which has the Power Take Off, (PTO), mounted to it.3. Remove bolts (3) and drive opening cover (10). Remove PTO gear assembly (1). Remove six nuts (4).4. Remove adapter assembly (2) and o-ring seals (6) and (8).5. If necessary, remove bearing sleeves (9) and (5) for the idler gear and the PTO gear (1). Make note of the positioning of the oil holes in the bearings. Proper location of the holes during installation is necessary for lubrication. The following steps are for the installation of the PTO Assembly.6. Install bearing sleeves (5) and (9). Be sure to align oil holes.7. Install PTO assembly in the gear train housing. Coat the bearing sleeves with clean engine oil. Install o-ring seal (8). Position adapter assembly (2) on the studs and install the nuts8. Install o-ring seal (6), drive opening cover (10) and bolts (3).9. Install the gear train housing on the engine block.10. Install the idler gear. Apply 5P3414 Pipe Sealant to the threads of the bolts and install. Torque to 135 15 N m (100 11 lb ft).
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.
End By:a. install flywheel housing
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101402-9363
INJECTION-PUMP ASSEMBLY