101402-9423 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029423

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9423 1014029423

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Cross reference number

ZEXEL 101402-9423 1014029423

Zexel num

Bosch num

Firm num

Name

101402-9423

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 157 157 157

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

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 8.9

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 48.3 47.3 49.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13 12 14

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.4++

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
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K=8 N1=1250r/min N2=800r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=7deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
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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)-
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a=(60deg)

Information:

1. Disconnect oil supply line (1) and oil drain tube (2). Remove the four mounting nuts and remove the turbocharger. Remove the gasket. The following steps are for the installation of the turbocharger.2. Apply 5P3931 Anti-Seize to turbocharger mounting studs. Position turbocharger gasket and turbocharger, then Install the four mounting nuts. Tighten the four mounting nuts to a torque of 54 5 N m (40 4 lb.ft.).3. Position gaskets and install drain tube (2) and supply line (1).Disassemble And Assemble Turbocharger
Start By:a. remove turbocharger 1. Remove bolts (1) and (2). Remove the compressor and turbine housings.2. Remove nut (3) and compressor wheel (4). Slide out turbine wheel (5) and shaft.3. Remove adapter plate snap ring (6).4. Use two screwdrivers and remove adapter plate (7).5. Remove bushings (8), spacers (9), and seals (10).6. Remove snap ring (11) and bushing (12).7. Remove snap ring (13) and bushing (14). The following steps are for the assembly of the turbocharger.8. Install bushing (12) and snap ring (11). Repeat for bushing (14) and snap ring (13).9. With th seals and shield (15) in place, install shaft and turbine wheel assembly (5).10. Install the spacers, bushings, plate, seals and adapter plate. Install the snap ring (not illustrated).
Do not allow any of the 7M7456 Locktite to get on the shaft. Damage to the turbocharger may occur.
11. Install compressor wheel (4) on the shaft. Put one drop of 7M7456 Locktite on the threads and install nut (3). Tighten nut (3) to a torque of 15.6 .7 N m (138 6 lb.in.).12. Position the turbine and compressor housings. Put 5P3931 Anti-Seize Compound on the bolts and install. Tighten bolts (1) for the compressor cover to a torque of 7.3 .6 N m (65 5 lb.in.). Tighten bolts (2), for the turbine housing to a torque of 15.8 .6 N m (140 5 lb.in.).End by:a. Install turbocharger