Information injection-pump assembly
ZEXEL
101402-9740
1014029740
Rating:
Service parts 101402-9740 INJECTION-PUMP ASSEMBLY:
1.
_
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
Cross reference number
ZEXEL
101402-9740
1014029740
Zexel num
Bosch num
Firm num
Name
101402-9740
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
8.9
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
38.1
37.1
39.1
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
465
465
465
Average injection quantity
mm3/st.
13
12
14
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.
85
80
90
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
(7)Rack difference between N = N3 and N = N4
----------
K=11 N1=1250r/min N2=800r/min N3=1250r/min N4=450r/min
----------
----------
K=11 N1=1250r/min N2=800r/min N3=1250r/min N4=450r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=16deg+-5deg b=29deg+-5deg
----------
----------
a=16deg+-5deg b=29deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At delivery
----------
----------
a=58deg+-5deg b=53deg+-5deg
----------
----------
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)
----------
----------
a=(60deg)
Information:
Start By:a. remove valve coversb. remove fuel injection lines 1. Use tool (A) and a 5P328 crowfoot wrench (7/8") to loosen the fuel injection line nut at the nozzle end.
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turn in the body.
2. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (1). Install plugs in the fuel injection nozzles. 3. Remove the nut that holds the adapters to the cylinder head assembly. Remove fuel injection line adapters (2).Install Fuel Injection Line Adapters
1. Check the condition of O-ring seal (1) on fuel injection line adapter (2) for damage. Make a replacement if necessary.2. Lubricate O-ring seal (1) with clean engine oil. Install fuel injection line adapter (2). Tighten the retaining nut to a torque of 13.6 2.7 N m (10 2 lb ft). 3. Check the condition of the O-ring seal on inner fuel line (3) for damage, and make a replacement if necessary. Install inner fuel line (3).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
4. Use tooling (A) to tighten the inner fuel line nuts to a torque of 42 6.8 N m (32 5 lb ft).End By:a. install fuel injection linesb. install valve covers
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turn in the body.
2. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (1). Install plugs in the fuel injection nozzles. 3. Remove the nut that holds the adapters to the cylinder head assembly. Remove fuel injection line adapters (2).Install Fuel Injection Line Adapters
1. Check the condition of O-ring seal (1) on fuel injection line adapter (2) for damage. Make a replacement if necessary.2. Lubricate O-ring seal (1) with clean engine oil. Install fuel injection line adapter (2). Tighten the retaining nut to a torque of 13.6 2.7 N m (10 2 lb ft). 3. Check the condition of the O-ring seal on inner fuel line (3) for damage, and make a replacement if necessary. Install inner fuel line (3).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
4. Use tooling (A) to tighten the inner fuel line nuts to a torque of 42 6.8 N m (32 5 lb ft).End By:a. install fuel injection linesb. install valve covers
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101402-9740
INJECTION-PUMP ASSEMBLY