101402-9430 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029430

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9430 1014029430

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Service parts 101402-9430 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8451

3. GOVERNOR 105419-2110

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:

101402-9254 as _

101402-9430 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-9430 1014029430

Zexel num

Bosch num

Firm num

Name

101402-9430

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 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.5 56.5 58.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 11.5 10.5 12.5

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 *

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)Main spring setting (5)Set idle sub-spring
----------
K=10
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Stopper bolt setting (3)Set the pump speed at aa (4)Set the pump speed at bb.
----------
aa=750r/min bb=900r/min
----------
a=14deg+-5deg b=5deg+-5deg c=6deg+-5deg

Stop lever angle

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

----------
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)

Information:

1. Remove bolts (1) and remove the oil pump pick-up and discharge tubes. 2. Remove two bolts (2) and remove the oil pump. The following step is for the installation of the oil pump.3. Position the oil pump and install and torque two bolts (2).4. Position the pick-up and discharge tubes and install bolts (1).End By:a. install oil panDisassemble And Assemble Oil Pump
Start By:a. remove oil pump 1. If necessary, remove the idler gear.2. Remove bolt (1) and remove relief valve spring (2) with relief valve (3).4. Use tooling (A) and remove input gear (4).
Before removing the input shaft and gear from the pump housing, be sure no burrs are on the input shaft. Burrs on the shaft may scratch and damage the pump housing.
5. Remove bolts (5) and separate the pump housing. Remove input shaft and gear (6) from the pump housing. Remove the driven gear from the housing. The following steps are for the assembly of the oil pump. Before pressing input gear (4) onto input shaft (6) be sure to install bolt (5), that is positioned under the input gear.6. Position input gear and shaft (6) in the pump housing. Press input gear (4) onto the input shaft until it is flush with the end of the shaft. Position the driven gear in the housing.7. Position the pump housings together. Install bolts (5). Install the idler gear if it was removed.8. Position relief valve spring (2), relief valve (3) and install bolt (1).End By:a. install oil pump