101402-9631 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029631

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9631 1014029631

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Service parts 101402-9631 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8720

3. GOVERNOR 105419-3070

4. SUPPLY PUMP 105220-7200

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:

101402-9631 as INJECTION-PUMP ASSEMBLY

101402-9654 as _

Cross reference number

ZEXEL 101402-9631 1014029631

Zexel num

Bosch num

Firm num

Name

101402-9631

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 4.2 4.15 4.25

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 10.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 85 84 86

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.6+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 16 15 17

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. 120 110 130

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
----------
K=8
----------

Speed control lever angle

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

----------
a=6deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb. (2)Stopper bolt setting (3)Use the pin above R = cc (4)Stopper bolt setting
----------
aa=1-0.5mm bb=0r/min cc=30mm
----------
a=13deg+-5deg b=(55deg)

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:

Start By:a. remove flywheel
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal with tool (A). 2. Install tool (C) as shown.3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve in loose.4. Remove tool (C) and the wear sleeve by hand. The following steps are for the installation of the crankshaft rear seal and wear sleeve. 5. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows:a. Put locator (1) in position on the crankshaft and install the three bolts that hold it in place.b. Put clean engine oil on the seal lip of seal (6) and on the outside diameter of wear sleeve (2).c. Install seal (6) on wear sleeve (2) from the end of the wear sleeve that has the bevel on the outside diameter. Make sure the lip of the seal is toward the inside of the engine and the bevel that is on the outside diameter of the wear sleeve is toward the outside of the engine when installed.d. Use 6V1541 Quick Cure Primer to clean the outside diameter of the crankshaft flange (3) and the inside diameter of wear sleeve (2).e. Put 9S3265 Retaining Compound on the outside diameter of crankshaft flange (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.f. Put wear sleeve (2) with seal (6) on locator (1). Put installer (4) on locator (1) and install nut (5). Put lubrication on the face of the washer and the nut.g. Tighten nut (5) until installer (4) comes in contact with locator (1).h. Remove tooling (A) and check the wear sleeve and seal for correct installation.End By:a. install flywheel