101402-3770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023770


101402-3770 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101402-3770 1014023770

Service parts 101402-3770 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-9220
3. GOVERNOR 105404-5000
4. SUPPLY PUMP 105220-7160
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER
14. NOZZLE
15. NOZZLE SET

Include in #1:

101402-3770 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-3770 1014023770


Zexel num
Bosch num
Firm num
Name
101402-3770 
 
   
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   131424-3420
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   2.5 2.45 2.55
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   A
Rack position   9.4
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   90 89 91
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   38.7 38.7
Boost pressure mmHg   290 290
Hydraulic cylinder ON   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.1+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Hydraulic cylinder ON   *
Remarks
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.   90 90 100
Fixing the lever   *
Boost pressure kPa   38.7 38.7
Boost pressure mmHg   290 290
Hydraulic cylinder OFF   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   R1-0.5
Boost pressure kPa   11.3 8.6 14
Boost pressure mmHg   85 65 105
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   R1(9.4)
Boost pressure kPa   25.3 18.6 32
Boost pressure mmHg   190 140 240

Test data Ex:

Governor adjustment

Test data 101402-3770
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)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Boost compensator stroke: BCL (7)When the hydraulic cylinder is ON (P1)
----------
K=12 BCL=0.5+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------

Speed control lever angle

Test data 101402-3770
F:Full speed I:Idle S:Stop (1)Speed = aa (active mode) (2)- (3)Speed = bb (normal mode) (4)-
----------
aa=1150r/min bb=1050r/min
----------
a=14deg+-3deg b=29deg+-5deg c=32deg+-3deg d=5deg+-5deg

Stop lever angle

Test data 101402-3770
N:Pump normal S:Stop the pump.
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

Test data 101402-3770
(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min




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