101502-9080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015029080

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101502-9080 1015029080

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Cross reference number

ZEXEL 101502-9080 1015029080

Zexel num

Bosch num

Firm num

Name

101502-9080

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 131425-2420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-5-4- 2

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 72 71.5 72.5

Difference between angles 2
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 3
Cal 1-4 deg. 216 215.5 216.5

Difference between angles 4
Cyl.1-2 deg. 288 287.5 288.5

Injection quantity adjustment

Adjusting point A

Rack position 10.3

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 77 75.5 78.5

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 325 325 325

Average injection quantity mm3/st. 15 13 17

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1130

Advance angle deg. 3.5 3 4

Remarks
Finish

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)Set idle sub-spring (4)Main spring setting (5)Rack difference from N = N1
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K=14 N1=1200r/min
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Speed control lever angle

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

----------
a=19deg+-5deg b=36deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Use the hole at R = aa
----------
aa=60mm
----------
a=19deg+-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=(120deg)

Information:

start by: a) separation of governor from fuel injection pump housing1. Remove the cover (16) from rack centering pin. Move the rack to the fuel "OFF" position, and push in on the centering pin (15). Install the cover (16) as shown to keep the centering pin in position during disassembly and assembly of injection pump housing. 2. Move the rack toward the fuel "ON" position until the slot in rack (13) is against the rack centering pin (15). The rack is now in the "CENTER" position.
Do not try to remove the fuel injection pumps if the rack is not in "CENTER" position.
3. Remove the fuel injection pumps as follows: a) Remove the caps and felt washer (1).b) Install wrench (A), and remove the bushing (2) from housing. c) Install extractor (B).d) Remove the bushing (2) and wrench (A).e) Remove the seal (3).f) Lift the fuel injection pump up and out of housing.g) Remove the spacer (9). Keep the spacer (9) together with its respective fuel injection pump. Put identification on the pumps and spacers as to their location in the pump housing.4. Disassemble the fuel injection pumps as follows: a) Remove the ring (7), bonnet (4), check valve (6), and spring (5) from barrel (8).b) Remove the plunger assembly (11), washer (12), and spring (10) from barrel (8).
Be very careful when disassembling and assembling the fuel injection pumps to prevent damage to the plunger surfaces. The barrel and plunger assemblies are fitted together, and must not be used with other barrels or plunger assemblies.
5. Remove the rack centering pin, spring, and cover. 6. Remove the rack (13), and lifters (14). Put identification on the lifters as to their location in the pump housing. Keep the lifters with their respective pumps and spacers. 7. Remove the bolt, lock, and plate (17) from the camshaft. Remove the spring and gear assembly (18).8. Remove the camshaft (20) from pump housing.9. Remove the rack bearings (19) from housing. 10. Use tool setup (C) to remove the camshaft bearings from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Use tool group (D) to install the rack bearing in the accessory drive housing end of injection pump housing.2. Install the rack bearing in governor end of housing using tool setup (E). The bearing must be installed .195 .005 in. (4.95 0.13 mm) below outside face of pump housing.3. Use tool group (C) to install the camshaft bearings in housing. Make sure the oil holes in bearings are in alignment with oil holes in pump housing. 4. Put clean engine oil on the camshaft bearings. Install the camshaft (1) in pump housing. 5. Install the gear (3), spring, plate, lock, and bolt (2) on the camshaft.6. Put clean engine oil on lobes of camshaft. 7. Install the lifters (4) in their respective positions in pump housing. Install the spacers in their correct locations in housing. If new lifters are to be installed, it will be necessary to check the timing