101402-9370 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9370 1014029370

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Service parts 101402-9370 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8451

3. GOVERNOR 105419-2070

4. SUPPLY PUMP 105220-7170

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-9370 as INJECTION-PUMP ASSEMBLY

Include in #2:

104700-9160 as _

Cross reference number

ZEXEL 101402-9370 1014029370

Zexel num

Bosch num

Firm num

Name

101402-9370

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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.6 3.55 3.65

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 9.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 34 33 35

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 450 450 450

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 -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 55 65

Fixing the lever *

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=13 N1=1000r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=5deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Left hand table (2)Left hand table
----------

----------
a=2.5deg+-5deg b=53deg+-5deg c=19deg+-5deg d=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)

Information:

(1) Governor front housing.(2) Joint face between front housing and rear housing.(3) Governor rear housing.(4) Dashpot spring (7C4466). Color code ... one dark green stripeRate test:a. Put a load on spring of ... 20 N (4.5 lb)b. Compress spring an additional ... 5 mm (.197 in)c. Total test force ... 50.0 1.5 N (11.25 .34 lb)d. Free length after test ... 39.5 mm (1.555 in)(5) Tighten 8 bolts to a torque of ... 10 1 N m (90 9 lb in)(6) Shims. Install shims as required to provide dimension (A) between joint face (2) of governor housing and riser groove. Refer to Disassembly and Assembly Section of this Service Manual, for the correct tools and procedure to check dimension (A).Dimension (A) ... 20.00 0.08 mm (.787 .003 in)(7) Riser.(8) Riser lever swivel.(9) Spring group (9Y4027) Inner spring (9Y2589) ... Low idle springColor code ... one violet stripe, one dark blue stripeRate test:a. Put a load on spring of ... 60 N (13.5 lb)b. Compress spring an additional ... 10 mm (.394 in)c. Total test force ... 130.0 2.6 N (29.25 .6 lb)d. Free length after test ... 47.02 0.50 mm (1.851 .02 in)Outer spring (9Y4028) ... High idle springColor code ... one red stripe, one light blue stripeRate test:a. Put a load on spring of ... 100 N (22.5 lb)b. Compress spring an additional ... 10 mm (.394 in)c. Total test force ... 252.0 4.8 N (56.7 1.1 lb)d. Free length after test ... 62.31 0.50 mm (2.453 .02 in)(10) Shims. Install shims as required to provide the correct governor spring preload dimension. Refer to the Diassembly and Assembly Section of this Service Manual, for the correct tools and procedure to check the governor spring preload dimension.
View Into Rear Housing(11) Torque lever.
View A-A(12) Throttle spring (7W9526) (part of governor front housing assembly). Type ... torsionalRate per 360° ... 1.054 N m (9.38 lb in)Preload in assembled position ... 270°(13) Torque cam.
View B-B(8) Riser lever swivel.(11) Torque lever.(13) Torque cam.(15) Torque cam setscrew. Refer to the Disassembly And Assembly Section of this Service Manual, for the complete procedure for setting torque cam. The 1U7310 Torque Cam Adjustment Tool (part of 1U7315 Governor Disassembly And Assembly Tool Group) is required to check/adjust the torque cam.