Information injection-pump assembly
ZEXEL
101602-3710
1016023710
Rating:
Cross reference number
ZEXEL
101602-3710
1016023710
Zexel num
Bosch num
Firm num
Name
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
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
4
3.95
4.05
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
10
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
95.1
94.1
96.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
11.7
10.5
12.9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Idle sub spring setting: L1.
----------
K=16 L1=7-0.5mm
----------
----------
K=16 L1=7-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Pump speed = bb
----------
aa=900r/min bb=750r/min
----------
a=29deg+-5deg b=7deg+-5deg c=6.5deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=29deg+-5deg b=7deg+-5deg c=6.5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At shipping
----------
----------
a=11.5deg+-5deg b=53deg+-5deg
----------
----------
a=11.5deg+-5deg b=53deg+-5deg
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some instances of issues with the following fuel injection pumps:
Table 1
Part Number Description
295-0435 Fuel Injection Pump Gp
348-6930 Pump
415-4313 Pump
420-4524 Fuel Injection Pump
422-5257 Fuel Injection Pump
443-3226 Fuel Injection Pump The issue may be reported as low engine power or the high idle speed may be inconsistent. Most issues have been reported below 200–300 hours of service.Solution
Note: Do not attempt to adjust the fuel pump or repair the fuel pump.Install a replacement fuel pump of the same part number. Refer to Disassembly and Assembly, Fuel Injection Pump - Remove and Disassembly and Assembly, Fuel Injection Pump - Install for the correct procedure.Retain the removed fuel pump for 30 days. The fuel pump will be requested for return using the Send It Back (SIB) process.
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some instances of issues with the following fuel injection pumps:
Table 1
Part Number Description
295-0435 Fuel Injection Pump Gp
348-6930 Pump
415-4313 Pump
420-4524 Fuel Injection Pump
422-5257 Fuel Injection Pump
443-3226 Fuel Injection Pump The issue may be reported as low engine power or the high idle speed may be inconsistent. Most issues have been reported below 200–300 hours of service.Solution
Note: Do not attempt to adjust the fuel pump or repair the fuel pump.Install a replacement fuel pump of the same part number. Refer to Disassembly and Assembly, Fuel Injection Pump - Remove and Disassembly and Assembly, Fuel Injection Pump - Install for the correct procedure.Retain the removed fuel pump for 30 days. The fuel pump will be requested for return using the Send It Back (SIB) process.