Information injection-pump assembly
ZEXEL
101402-9742
1014029742
Rating:
Cross reference number
ZEXEL
101402-9742
1014029742
Zexel num
Bosch num
Firm num
Name
101402-9742
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
7.4+-0.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
9.9++
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
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K=14 N1=1250r/min N2=800r/min N3=1250r/min N4=450r/min
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K=14 N1=1250r/min N2=800r/min N3=1250r/min N4=450r/min
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Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
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a=15deg+-5deg b=25deg+-5deg
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a=15deg+-5deg b=25deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal stop
----------
----------
a=58deg+-5deg b=53deg+-5deg
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----------
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)-
----------
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a=(60deg)
----------
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a=(60deg)
Information:
1. Remove the two bolts, and remove the fuel ratio control from the governor. Remove O-ring seal (1) from the fuel ratio control. 2. Put tooling (A) in a vise as shown so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in tooling (A). Remove cover (2) and the O-ring from fuel ratio control.
There is spring force behind cover (3). Hold cover (3) in position, and slowly remove the bolts that hold it to release the spring force.
3. Remove cover (3) from housing (4). 4. Remove spring (7), washer (5), and diaphragm (8) from retainer (6). Remove retainer (6) from housing (9). 5. Remove nut (14) from extension (13), and remove the extension from retainer (6). Remove valve (10), spring (11) and O-ring seal (12) from the extension. 6. Remove spring (16), retainer (15) and spring (17) from the housing. 7. Remove piston assembly (18) from the housing. 8. Use tooling (B), and remove snap ring (19) and the wave washers from valve assembly (20). Remove piston assembly (21) from the valve assembly.9. Remove seal (22) from piston (21). 10. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.Assemble Fuel Ratio Control
1. If valve (1) and stem (2) are loosened or partially unscrewed, the valve assembly should be replaced with new. 2. Put seal (4) on piston (3), and put piston (3) on valve assembly (5). 3. Put two wave washers in position on valve (5), and use tooling (A) to install the snap ring on the valve assembly. 4. Place housing (7) on tooling (B), and put tooling (C) into the bore of the housing. Lubricate tooling (C) with clean engine oil.5. Put a small amount of clean oil on the seal of the piston assembly, and push piston assembly (6) into position with a smooth swift motion. 6. Place spring (8) and retainer and spring (9) in position in housing (7). 7. Put O-ring seal (12) on extension (13). Put spring (11) and valve (10) in position on the extension.8. Lubricate O-ring seal (12) with clean engine oil. Install extension (13) in retainer (14). Install nut (15). 9. Put diaphragm (18), washer (17) and spring (16) in position on retainer (14). Install retainer (14) in housing (7). 10. Hold retainer (14) in position, and install cover (19) on the housing. Install the bolts that hold the cover, and tighten them to a torque of 9 3 N m (7 2 lb ft). 11. Inspect the O-ring for cover (20). Replace the O-ring if worn or broken. Install the cover. 12. Put O-ring seal (21) in position on the fuel ratio control.13. Put the fuel ratio control in position on the governor. Make sure the flange on the end of the fuel ratio control is behind the groove (slot) in the lever. Install the bolts that hold the fuel ratio control in position. See the Testing
There is spring force behind cover (3). Hold cover (3) in position, and slowly remove the bolts that hold it to release the spring force.
3. Remove cover (3) from housing (4). 4. Remove spring (7), washer (5), and diaphragm (8) from retainer (6). Remove retainer (6) from housing (9). 5. Remove nut (14) from extension (13), and remove the extension from retainer (6). Remove valve (10), spring (11) and O-ring seal (12) from the extension. 6. Remove spring (16), retainer (15) and spring (17) from the housing. 7. Remove piston assembly (18) from the housing. 8. Use tooling (B), and remove snap ring (19) and the wave washers from valve assembly (20). Remove piston assembly (21) from the valve assembly.9. Remove seal (22) from piston (21). 10. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.Assemble Fuel Ratio Control
1. If valve (1) and stem (2) are loosened or partially unscrewed, the valve assembly should be replaced with new. 2. Put seal (4) on piston (3), and put piston (3) on valve assembly (5). 3. Put two wave washers in position on valve (5), and use tooling (A) to install the snap ring on the valve assembly. 4. Place housing (7) on tooling (B), and put tooling (C) into the bore of the housing. Lubricate tooling (C) with clean engine oil.5. Put a small amount of clean oil on the seal of the piston assembly, and push piston assembly (6) into position with a smooth swift motion. 6. Place spring (8) and retainer and spring (9) in position in housing (7). 7. Put O-ring seal (12) on extension (13). Put spring (11) and valve (10) in position on the extension.8. Lubricate O-ring seal (12) with clean engine oil. Install extension (13) in retainer (14). Install nut (15). 9. Put diaphragm (18), washer (17) and spring (16) in position on retainer (14). Install retainer (14) in housing (7). 10. Hold retainer (14) in position, and install cover (19) on the housing. Install the bolts that hold the cover, and tighten them to a torque of 9 3 N m (7 2 lb ft). 11. Inspect the O-ring for cover (20). Replace the O-ring if worn or broken. Install the cover. 12. Put O-ring seal (21) in position on the fuel ratio control.13. Put the fuel ratio control in position on the governor. Make sure the flange on the end of the fuel ratio control is behind the groove (slot) in the lever. Install the bolts that hold the fuel ratio control in position. See the Testing
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101402-9742
INJECTION-PUMP ASSEMBLY