101402-9671 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029671

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9671 1014029671

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Service parts 101402-9671 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8740

3. GOVERNOR 105419-2960

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:

101402-9671 as INJECTION-PUMP ASSEMBLY

101405-9491 as _

Cross reference number

ZEXEL 101402-9671 1014029671

Zexel num

Bosch num

Firm num

Name

101402-9671

INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE

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 9.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 59 58 60

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.8+-0.5

Pump speed r/min 790 790 790

Average injection quantity mm3/st. 9.5 8.5 10.5

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. 90 85 95

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

Speed control lever angle

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

----------
a=1deg+-5deg b=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At delivery
----------

----------
a=58deg+-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:

Marks For Tightening Connecting Rod Bolts-7E5996 Connecting Rod Assembly(1) Bore in connecting rod for piston pin bearing ... 55.436 0.013 mm (2.1825 .0005 in) The connecting rod must be heated for installation of piston pin bearing. Do not use a torch.(2) Distance rod may be heated to 175 to 260°C (347 to 500°F) to install the piston pin bearing ... 85.0 mm (3.35 in)(3) Bore in bearing for piston pin (new) ... 50.830 0.008 mm (2.0012 .0003 in) Diameter of piston pin (new) ... 50.795 0.005 mm (1.9998 .0002 in)Thoroughly lubricate piston pin with clean engine oil prior to inserting into piston group and rod assembly.Maximum permissible clearance between bearing and piston pin (worn) ... 0.25 mm (.010 in)(4) Bearing joint must be assembled at either location on centerline through the connecting rod bore ... 5°Make reference to Special Instruction, Form No. SMHS7295 for use of pin bearing removal and installation tools and procedures.(5) Distance between center of bearings ... 261.62 0.05 mm (10.300 .002 in)(6) Bore in connecting rod for bearing with nuts tightened to specifications (8) ... 96.200 0.013 mm (3.7874 .0005 in)(7) Location for etching cylinder number on connecting rod and cap. Rods and caps are to be marked with numbers 1 through 6 on the same side of the rod as the bearing tab slots.(8) Tighten connecting rod bolts as follows: a. Before installing bolts, lubricate bolt threads and seating faces of the caps with 2P2506 Thread Lubricant.b. Tighten each bolt to ... 90 8 N m (66 6 lb ft)c. Put an alignment mark on each cap and bolt.d. Tighten each bolt an additional ... 90 5° (1/4 turn)(9) Bore in bearing for crankshaft rod journal ... 90.112 0.028 mm (3.5477 .0011 in) Clearance between bearing and crankshaft (new) ... 0.062 to 0.160 mm (.0024 to .0063 in)Maximum permissible clearance between bearing and crankshaft (worn) ... 0.20 mm (.008 in) Bearings are available in 0.63 mm (.025 in) and 1.27 mm (.050 in) smaller than original size.