Information injection-pump assembly
ZEXEL
101602-1431
1016021431
Rating:
Service parts 101602-1431 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME016655
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101602-1431
as INJECTION-PUMP ASSEMBLY
Include in #2:
104213-3220
as _
Cross reference number
ZEXEL
101602-1431
1016021431
Zexel num
Bosch num
Firm num
Name
101602-1431
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
131424-5520
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
1-5-3-6-
2-4
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.8
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
71.5
70.5
72.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.4+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
70
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)Supplied with torque spring not set.
(4)RACK LIMIT
(5)Set idle sub-spring
(6)Main spring setting
----------
K=11
----------
----------
K=11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(7deg)+-5deg b=(23deg)+-5deg
----------
----------
a=(7deg)+-5deg b=(23deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(130deg)
----------
aa=11deg
----------
a=(130deg)
Information:
Illustration 1 g01068766
Inlet fuel line (fuel transfer pump to cylinder head) (1) Connector (2) Hose assembly (3) Fuel transfer pump
Remove connector (1) and hose assembly (2) from the fuel transfer pump (3). Refer to Illustration 1. Retain these parts for the reinstallation.
Illustration 2 g01068729
Outlet fuel line (fuel transfer pump to secondary fuel filter) (4) Adapter (5) Tee (6) Elbow (7) Hose assembly
Remove adapter (4), tee (5), elbow (6), and hose assembly (7) from the fuel transfer pump (3). Refer to Illustration 2. Retain these parts for the reinstallation.Note: Modifications to the tools may need to be made in order to reduce interference with engine components. Refer to Illustration 3.
Illustration 3 g01007381
Modified 2P-5494 crowfoot wrench
Illustration 4 g01068745
(3) Fuel transfer pump (8) Bolt (9) Bolt (10) Washer (11) Adapter (15) HEUI pump (21) Clip
Remove the bolt (8) and the clip (21) from the top of the fuel transfer pump. Refer to Illustration 4.
Remove the bolt (9) and the washer (10) from the bottom of the fuel transfer pump (3). Refer to Illustration 4.
Remove fuel transfer pump (3). Refer to Illustration 4.
Illustration 5 g01068776
(12) 45 ° adapter (13) Hose assembly (14) Straight connector (15) HEUI pump
Remove hose assembly (13) from 45 degree adapter (12) and straight connector (14) by using removal tool (A). Refer to Illustration 5.
Remove 45 degree adapter (12) from the HEUI pump (15). Remove straight adapter (14) from the cylinder head. Discard the parts. Refer to Illustration 5.Installation of the Engine Oil Lines Group
Illustration 6 g01068779
(16) 247-3755 Tube As (17) 6V-8636 Connector (18) 221-3494 O-Ring Seal (19) 214-7568 O-Ring Seal (20) 6V-8724 Elbow
Apply a light coat of oil to the O-rings (18) and (19) during installation. Install the O-ring (18) on
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101602-1431
INJECTION-PUMP ASSEMBLY