102700-0150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1027000150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 102700-0150 1027000150

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Service parts 102700-0150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9730

3. GOVERNOR 105921-5810

4. SUPPLY PUMP

105220-6110

5. AUTOM. ADVANCE MECHANIS 102720-0031

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5470

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-1350

15. NOZZLE SET

Include in #1:

102700-0150 as INJECTION-PUMP ASSEMBLY

107691-2214 as _

107691-2215

Cross reference number

ZEXEL 102700-0150 1027000150

Zexel num

Bosch num

Firm num

Name

102700-0150

DPICO

INJECTION-PUMP ASSEMBLY
K-1 * Q

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 131424-6220

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 10.7

Pump speed r/min 1000 1000 1000

Each cylinder's injection qty mm3/st. 53.5 52.1 54.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Each cylinder's injection qty mm3/st. 8 6.7 9.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 53.5 52.5 54.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.7)

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 57 53 61

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 680 680 680

Average injection quantity mm3/st. 44.5 42.5 46.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 67 67 72

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1400

Advance angle deg. 0.5

Load 3/4

Timer adjustment_02

Pump speed r/min 1750

Advance angle deg. 6 5.5 6.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G93
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(44deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed = dd and rack position = not exceeding ee. (4)- (5)Rack position corresponding to ff (6)Free (at delivery)
----------
aa=40mm bb=1750r/min cc=(6.2)-0.5mm dd=300r/min ee=(8)mm ff=16mm
----------
a=25deg+-5deg b=20deg+-5deg c=35deg+-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=10deg
----------
a=(130deg)

Information:

Termination Date
January 31, 1993Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34325)
3208 (9WC1-730; 5CD1-5868; 62W1-68596; 93Z1-8374)
Remanufactured Fuel Pump Part Numbers
0R07660R09030R23840R23860R09020R23740R23850R2877 The above list of remanufactured pumps are affected only if they are stamped with a date code of 12/91 (UMDU) or earlier.
Parts Needed
Not Applicable
Action Required
Before installing or delivering any of the affected product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with: - Fuel Injector Cleaner or
- Carburetor/Choke Cleaner
4. Allow the components to soak in cleaning solution for 45 minutes, then rotate the engine crankshaft to rotate the fuel injection pump (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.5. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
It is a .5-hr. job to inspect the pump. An additional .5-hr. may be claimed if cleaning is required.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.