101602-7710 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016027710

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-7710 1016027710

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Cross reference number

ZEXEL 101602-7710 1016027710

Zexel num

Bosch num

Firm num

Name

101602-7710

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.5 72 75

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 340 340 340

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.

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)The torque control spring does not operate. (4)Set idle sub-spring (5)Main spring setting
----------
K=10
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Speed control lever angle

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

----------
a=1deg+-5deg b=18deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=46deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(10deg)

Information:

Fuel Filter
(For in-line fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump and fuel hoses.
(For distributor-type fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump and fuel hoses.
Fuel Injection Pipe, Fuel Leak-Off Pipe and Fuel Injection Nozzle
(For in-line fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump, nozzle inlet connectors and injection pipes.
(For distributor-type fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump, nozzle inlet connectors and injection pipes.
Fuel Injection Pump
(In-line fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the fuel injection pump.
(Distributor-type fuel injection pump)
To prevent dust from entering the fuel system, cover all openings in the injection pump.
Removal of Fuel Injection Pump
(1) Check the alignment marks stamped on the flange of the fuel injection pump and the pump mounting flange.(2) Remove the front cover from the engine.(3) Place alignment marks on the fuel injection pump gear and idler gear.(4) Unscrew the mounting bolts from the fuel injection pump flange, and remove the fuel injection pump together with the flange from the front plate. (a) After the fuel injection pump is removed, do not turn the engine.(b) When removing the pump gear, loosen the gear retaining nut while the pump is mounted on the engine.
Removal of fuel injection pump (1)
Removal of fuel injection pump (2)