101402-9540 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029540

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9540 1014029540

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Service parts 101402-9540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8210

3. GOVERNOR 105419-2480

4. SUPPLY PUMP 105220-7090

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6011

11. Nozzle and Holder 34361-03011

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3330

14. NOZZLE 105017-1820

15. NOZZLE SET

Include in #1:

101402-9510 as _

101402-9540 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-9540 1014029540

Zexel num

Bosch num

Firm num

Name

101402-9540

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 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 3.2 3.15 3.25

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 8.4

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 72.5 71.5 73.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.8+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 11 9.7 12.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80 85

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=11 N1=1200r/min N2=700r/min
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Speed control lever angle

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

----------
a=24deg+-5deg b=8deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Hold the boss against the stop side (2)Use the hole at R = aa
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Loosen two hose clamps (1) and remove the hose from the tube assembly.2. Remove tube assembly (2) and the gasket.3. Disconnect hose assembly (3). 4. Loosen hose clamps (4) and remove the hose from the pipe. 5. Remove three bolts (6) and engine oil cooler assembly (5). Inspect all gaskets and make replacements if necessary. Install in reverse order.End By:a. install oil filter baseDisassemble And Assemble Engine Oil Cooler
Start By:a. remove engine oil cooler
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
Before assembly inspect gaskets and the O-ring seals for damage and make needed replacements. 1. Remove bonnet (1) and pipe (3) from core assembly (2). 2. Remove elbows (4) from the core assembly. Bolts (5) have twelve point heads. 3. Clean the tubes of the cooler core with a 3.96 mm (.156 in) diameter rod. Remove the o-ring seals and inspect for damage. Replace if necessary. Assemble in reverse order.End By:a. install engine oil cooler