Information injection-pump assembly
ZEXEL
101402-9730
1014029730
Rating:
Cross reference number
ZEXEL
101402-9730
1014029730
Zexel num
Bosch num
Firm num
Name
101402-9730
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
78.5
77.5
79.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
76
76
Boost pressure
mmHg
570
570
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.5+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
12
10
14
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.
70
70
80
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
900
900
900
Rack position
R1-1
Boost pressure
kPa
17.3
12
22.6
Boost pressure
mmHg
130
90
170
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(10.6)
Boost pressure
kPa
66.7
64
69.4
Boost pressure
mmHg
500
480
520
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)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
----------
K=10 BCL=1+-0.1mm
----------
----------
K=10 BCL=1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=23deg+-5deg b=28deg+-5deg
----------
----------
a=23deg+-5deg b=28deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=32deg+-5deg b=50deg+-5deg
----------
----------
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
----------
L=7.3mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=1100r/min r2=1100r/min r3=1100r/min r4=- r5=- r6=- Q1=- Q2=78.5+-1mm3/st Q3=- Q4=- Q5=- Q6=- c1=- c2=+-3.5% c3=- c4=- c5=- c6=- a7=26 a8=25 a9=24 a10=23 a11=22 a12=21 a13=20 a14=19 a15=18 a16=17 a17=16 a18=15 a19=- a20=- a21=- a22=- a23=- a24=- a25=- a26=- a27=- a28=- r7=1300r/min r8=1250r/min r9=1200r/min r10=1150r/min r11=1100r/min r12=1050r/min r13=1000r/min r14=950r/min r15=900r/min r16=850r/min r17=800r/min r18=750r/min r19=- r20=- r21=- r22=- r23=- r24=- r25=- r26=- r27=- r28=- R7=1395+-32r/min R8=1340+-31r/min R9=1290+-30r/min R10=1235+-28r/min R11=1180+-27r/min R12=1130+-26r/min R13=1075+-25r/min R14=1020+-23r/min R15=965+-22r/min R16=915+-22r/min R17=860+-20r/min R18=805+-18r/min R19=- R20=- R21=- R22=- R23=- R24=- R25=- R26=- R27=- R28=-
----------
L=7.3mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=1100r/min r2=1100r/min r3=1100r/min r4=- r5=- r6=- Q1=- Q2=78.5+-1mm3/st Q3=- Q4=- Q5=- Q6=- c1=- c2=+-3.5% c3=- c4=- c5=- c6=- a7=26 a8=25 a9=24 a10=23 a11=22 a12=21 a13=20 a14=19 a15=18 a16=17 a17=16 a18=15 a19=- a20=- a21=- a22=- a23=- a24=- a25=- a26=- a27=- a28=- r7=1300r/min r8=1250r/min r9=1200r/min r10=1150r/min r11=1100r/min r12=1050r/min r13=1000r/min r14=950r/min r15=900r/min r16=850r/min r17=800r/min r18=750r/min r19=- r20=- r21=- r22=- r23=- r24=- r25=- r26=- r27=- r28=- R7=1395+-32r/min R8=1340+-31r/min R9=1290+-30r/min R10=1235+-28r/min R11=1180+-27r/min R12=1130+-26r/min R13=1075+-25r/min R14=1020+-23r/min R15=965+-22r/min R16=915+-22r/min R17=860+-20r/min R18=805+-18r/min R19=- R20=- R21=- R22=- R23=- R24=- R25=- R26=- R27=- R28=-
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(100deg)
----------
----------
a=(100deg)
Information:
Overheating
Possible Causes/Corrections
Low Coolant LevelIf the coolant level is too low, not enough coolant will go through the engine and radiator. This lack of coolant will not take enough heat from the engine and there will not be enough flow of coolant through the radiator to release the heat into the cooling air. Low coolant level is caused by leaks or wrong filling of the radiator. With the engine cool, be sure that coolant can be seen at the low end of the fill neck on the radiator top tank. Defective Temperature GaugeA temperature gauge which does not work correctly will not show the correct temperature. If the temperature gauge shows that the coolant temperature is too hot but other conditions are normal, either install a gauge you know is good or check the cooling system with the 4C6500 Digital Thermometer Group. Dirty RadiatorCheck the radiator for debris between the fins of the radiator core which prevents free air flow through the radiator core. Check the radiator for debris, dirt, or deposits on the inside of the radiator core which prevents free flow of coolant through the radiator. Loose Belt(s)Loose fan or water pump belts will cause a reduction in air or water flow. Tighten the belts according to Belt Tension Chart that is shown in Specification Section of this Service Manual. Defective Hose(s)Defective hoses with leaks can normally be seen. Hoses that have no visual leaks can "collapse" (pull together) during operation and cause a restriction in the flow of coolant. Hoses become soft and/or get cracks after a period of time. Hoses must be changed after 50,000 miles or a year of use. The inside can become loose, and the loose particles of the hose can cause a restriction in the flow of coolant. Shunt Line RestrictionA restriction of the shunt line from the radiator top tank to the engine front cover, or a shunt line not installed correctly, will cause a reduction in water pump efficiency. The result will be low coolant flow and overheating. Shutters Not Opening CorrectlyCheck the opening temperature of the shutters. The shutters must be completely closed at a temperature below the fully open temperature of the water temperature regulators. Also, verify that fan control switches or viscous fans are operating correctly. Defective Water Temperature RegulatorsA regulator that does not open, or only opens part of the way, can cause above normal heating. To test the thermostats, see the Testing and Adjusting Section of this Service Manual. Defective Water PumpA water pump with a loose impeller does not pump enough coolant for correct engine cooling. A loose impeller can be found by removing the water pump, and by pushing the shaft back and pulling it forward. If the impeller has no damage, check the impeller clearance. The clearance between the impeller and the housing is 0.56 to 1.50 mm (.022 to .059 in). Air In Cooling SystemAir can get into the cooling system in different ways. The most common causes are not
Possible Causes/Corrections
Low Coolant LevelIf the coolant level is too low, not enough coolant will go through the engine and radiator. This lack of coolant will not take enough heat from the engine and there will not be enough flow of coolant through the radiator to release the heat into the cooling air. Low coolant level is caused by leaks or wrong filling of the radiator. With the engine cool, be sure that coolant can be seen at the low end of the fill neck on the radiator top tank. Defective Temperature GaugeA temperature gauge which does not work correctly will not show the correct temperature. If the temperature gauge shows that the coolant temperature is too hot but other conditions are normal, either install a gauge you know is good or check the cooling system with the 4C6500 Digital Thermometer Group. Dirty RadiatorCheck the radiator for debris between the fins of the radiator core which prevents free air flow through the radiator core. Check the radiator for debris, dirt, or deposits on the inside of the radiator core which prevents free flow of coolant through the radiator. Loose Belt(s)Loose fan or water pump belts will cause a reduction in air or water flow. Tighten the belts according to Belt Tension Chart that is shown in Specification Section of this Service Manual. Defective Hose(s)Defective hoses with leaks can normally be seen. Hoses that have no visual leaks can "collapse" (pull together) during operation and cause a restriction in the flow of coolant. Hoses become soft and/or get cracks after a period of time. Hoses must be changed after 50,000 miles or a year of use. The inside can become loose, and the loose particles of the hose can cause a restriction in the flow of coolant. Shunt Line RestrictionA restriction of the shunt line from the radiator top tank to the engine front cover, or a shunt line not installed correctly, will cause a reduction in water pump efficiency. The result will be low coolant flow and overheating. Shutters Not Opening CorrectlyCheck the opening temperature of the shutters. The shutters must be completely closed at a temperature below the fully open temperature of the water temperature regulators. Also, verify that fan control switches or viscous fans are operating correctly. Defective Water Temperature RegulatorsA regulator that does not open, or only opens part of the way, can cause above normal heating. To test the thermostats, see the Testing and Adjusting Section of this Service Manual. Defective Water PumpA water pump with a loose impeller does not pump enough coolant for correct engine cooling. A loose impeller can be found by removing the water pump, and by pushing the shaft back and pulling it forward. If the impeller has no damage, check the impeller clearance. The clearance between the impeller and the housing is 0.56 to 1.50 mm (.022 to .059 in). Air In Cooling SystemAir can get into the cooling system in different ways. The most common causes are not
Have questions with 101402-9730?
Group cross 101402-9730 ZEXEL
Mitsubishi-Heav
Nissan-Diesel
101402-9730
INJECTION-PUMP ASSEMBLY