Information injection-pump assembly
ZEXEL
101602-3831
1016023831
Rating:
Cross reference number
ZEXEL
101602-3831
1016023831
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
Overflow valve
132424-0620
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
1-5-3-6-
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
9.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
88.5
87.5
89.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.5+-0.5
Pump speed
r/min
930
930
930
Average injection quantity
mm3/st.
20
18.8
21.2
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)Tolerance for racks not indicated: +-0.05mm.
(3)Rack difference between N = N1 and N = N2
(4)Set idle sub-spring
----------
K=16 N1=750r/min N2=450r/min
----------
----------
K=16 N1=750r/min N2=450r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)After confirming stopping, set at idling for delivery.
(2)Pump speed = aa
(3)Stopper bolt setting
(4)Speed = bb (at shipping)
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=32deg+-3deg c=6deg+-5deg d=25deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=32deg+-3deg c=6deg+-5deg d=25deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
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.Note: The standard work for the laser mark has been updated.Problem
Illustration 1 g06273667During laser marking on these Reman 3400 HEUI injectors both Prime and Non-Prime injectors were marked with NP. This caused confusion with dealers and customers. The NP is thought to mean "Non-Prime" and the injectors are Prime injector part numbers. The prime injectors marked incorrectly with NP but were built and tested to the correct Prime part number and should be used in fuel systems for prime injectors. Dealers can remove the two letters if they decide the two letters cause too much confusion.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Illustration 2 g06273668
Prime HEUI injector
NP stands for "Non-Prime". Going forward only "Non-Prime" 3400 HEUI injectors will have the NP laser mark.
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.Note: The standard work for the laser mark has been updated.Problem
Illustration 1 g06273667During laser marking on these Reman 3400 HEUI injectors both Prime and Non-Prime injectors were marked with NP. This caused confusion with dealers and customers. The NP is thought to mean "Non-Prime" and the injectors are Prime injector part numbers. The prime injectors marked incorrectly with NP but were built and tested to the correct Prime part number and should be used in fuel systems for prime injectors. Dealers can remove the two letters if they decide the two letters cause too much confusion.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Illustration 2 g06273668
Prime HEUI injector
NP stands for "Non-Prime". Going forward only "Non-Prime" 3400 HEUI injectors will have the NP laser mark.