101402-9640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029640

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9640 1014029640

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Cross reference number

ZEXEL 101402-9640 1014029640

Zexel num

Bosch num

Firm num

Name

101402-9640

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 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 76 75 77

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 68 68

Boost pressure mmHg 510 510

Injection quantity adjustment_02

Adjusting point C

Rack position 8.4+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 8.5 12.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 75 85

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 675 675 675

Rack position R1-1

Boost pressure kPa 10 4.7 15.3

Boost pressure mmHg 75 35 115

Boost compensator adjustment_02

Pump speed r/min 675 675 675

Rack position R1(10.4)

Boost pressure kPa 54.7 48 61.4

Boost pressure mmHg 410 360 460

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
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K=11 BCL=1+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(21deg)+-5deg b=(14deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=32deg+-5deg b=50deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
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L=7.2mm
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a1=A a2=B a3=C a4=- r1=- r2=1100r/min r3=- r4=- Q1=- Q2=76+-1mm3/st Q3=- Q4=- c1=- c2=+-3.5% c3=- c4=- a5=26 a6=25 a7=24 a8=23 a9=22 a10=21 a11=20 a12=19 a13=18 a14=17 a15=- r5=1300r/min r6=1250r/min r7=1200r/min r8=1150r/min r9=1100r/min r10=1050r/min r11=1000r/min r12=950r/min r13=900r/min r14=850r/min r15=- R5=1395+-32r/min R6=1340+-31r/min R7=1290+-30r/min R8=1235+-28r/min R9=1180+-27r/min R10=1130+-26r/min R11=1075+-25r/min R12=1020+-23r/min R13=965+-22r/min R14=915+-22r/min R15=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)- (4)-
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a=(100deg)

Information:

Stand By:a. remove engineb. remove timing gear coverc. remove flywheel housingd. remove pistons and connecting rods
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Turn the crankshaft until the timing mark (C) on the crankshaft gear (1) is in alignment with the timing mark (C) on camshaft gear (2).2. Make a mark on the teeth of the fuel pump drive gear and the idler gear in their engaged position at location (X). Make a mark on the engaged teeth of idler gear and camshaft gear at location (Y). This will give assistance in the correct timing of the camshaft for the fuel injection pump during crankshaft installation. 3. Fasten a hoist to the crankshaft.4. Remove the caps for the main bearings.5. Remove the crankshaft. Weight of the crankshaft is 95 kg (210 lb.).6. Remove the main bearings from the main bearing caps. Remove the crankshaft main bearings from the cylinder block. 7. Use tool (A) to remove the crankshaft gear and the oil seal wear sleeve.Install Crankshaft
Install the bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.
1. Clean the bearing surfaces in the cylinder block. Install the upper halves of the main bearings in the block.2. Heat the crankshaft gear to a maximum temperature of 315° C (600° F). Install the gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all timing marks in alignment.3. Clean the bearing surfaces of the main bearing caps. Install the lower halves of the main bearings in the caps. When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances. 4. Check the main bearing clearances with Plastigage (B) as follows:a. Put a piece of Plastigage (B) in position as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
Do not turn the crankshaft when Plastigage (B) is in position.b. Install the main bearing caps. Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers and install the bolts. Tighten the bolts to a