Information injection-pump assembly
ZEXEL
101401-2142
1014012142
Rating:
Service parts 101401-2142 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2010A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-2142
1014012142
Zexel num
Bosch num
Firm num
Name
101401-2142
INJECTION-PUMP ASSEMBLY
14BD PE4AD PE
14BD PE4AD PE
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
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-3-4-2
Pre-stroke
mm
4.3
4.27
4.33
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.3
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
83
81
85
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9+-0.5
Pump speed
r/min
315
315
315
Average injection quantity
mm3/st.
9
7.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.3)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
83
82
84
Basic
*
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
91
87
95
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-(1.2)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
37.6
33.6
41.6
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
D
Rack position
11.2
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
49.5
47.5
51.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
E
Rack position
R2(R1-0.
3)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
65.2
61.2
69.2
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_08
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
109
99
119
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
11.2
Boost pressure
kPa
2
2
4
Boost pressure
mmHg
15
15
30
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R1+1.1
Boost pressure
kPa
9.3
9.3
9.3
Boost pressure
mmHg
70
70
70
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
(1000)
Advance angle
deg.
1.25
0.65
1.25
Load
4/4
Timer adjustment_04
Pump speed
r/min
1200
Advance angle
deg.
1.25
0.65
1.25
Load
3/4
Timer adjustment_05
Pump speed
r/min
1500
Advance angle
deg.
4.5
4.2
4.8
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Boost compensator stroke: BCL
(3)Idle increase set point (air cylinder's negative pressure supply: P1)
----------
T1=D20 BCL=(1.2)+-0.1mm P1=392+98kPa(4+1kgf/cm2)
----------
----------
T1=D20 BCL=(1.2)+-0.1mm P1=392+98kPa(4+1kgf/cm2)
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=50mm
----------
a=22.5deg+-5deg b=39deg+-3deg
----------
aa=50mm
----------
a=22.5deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=40deg+-5deg b=40deg+-5deg
----------
----------
a=40deg+-5deg b=40deg+-5deg
0000001501 AIR CYLINDER
(A): Speed lever
(B): Set bolt
(C): air cylinder
(D): nut
(E): fix
1. Air cylinder adjustment procedure
(1)With the speed lever in the idling position, temporarily set the clearance between speed lever (A) and set bolt (B) at approximately L1.
(2)Set the speed to N1 and supply positive pressure P1 to the air cylinder (C).
(3)Gradually push set bolt (B) out (approximately L2) and tighten nut (D) where the speed is N2 and the rack position is Ra.
(4)Apply positive pressure P1 several times.
(5)Confirm that the lever returns to the idle position at positive pressure P2.
(6)Also, confirm that the rack position is Rb at air pressure P1.
----------
L1=(9)mm L2=(6)mm Ra=8.5~8.7mm Rb=8.5~8.7mm N1=475r/min N2=475r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------
----------
L1=(9)mm L2=(6)mm Ra=8.5~8.7mm Rb=8.5~8.7mm N1=475r/min N2=475r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
1. Remove the bolt and lock that holds suction bell (1) to the oil pan plate. Remove two bolts (4) that hold the elbow to the oil pump.
Oil pump idler gear (2) can fall off the pump when the pump is removed. To prevent injury, always hold the gear on the pump when the pump is removed.
2. Remove the bolts and locks that hold the oil pump to the engine. Remove oil pump (3).3. Install idler gear (2) on oil pump (3). Put the oil pump in position on the engine as shown with idler gear (2) engaged with the crankshaft gear. Install the bolts and locks that hold the oil pump to the engine.4. Install bolts (4) that hold the elbow to the oil pump.5. Install the bolt and lock that hold suction bell (1) to the oil pan plate.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump (3304) or remove oil pump (3306) 1. Remove idler gear (2). Remove the bearing from the idler gear with Tool (B).2. Remove suction bell (1).3. Remove the bolt and the washer from the oil pump drive gear. 4. Remove the drive gear from the shaft with Tool (A).5. Remove the key from the pump shaft.6. Remove bolts (3) from the pump body. 7. Remove body (8), two gears (7), the keys and spacer (4) from the pump.8. Remove two shafts (5) and the gears.9. Remove bolts (6), the cover and the pressure relief valve from the body. 10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with Tool (B).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with Tool (A) and a press as follows:a. Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is 1.52 mm (.060 in) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with Tool (A) and a press as follows:a. Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump body. Make sure the joints in the bearings are at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check the condition of the relief valve. Check the condition and specifications for all the parts of the oil pump before
Oil pump idler gear (2) can fall off the pump when the pump is removed. To prevent injury, always hold the gear on the pump when the pump is removed.
2. Remove the bolts and locks that hold the oil pump to the engine. Remove oil pump (3).3. Install idler gear (2) on oil pump (3). Put the oil pump in position on the engine as shown with idler gear (2) engaged with the crankshaft gear. Install the bolts and locks that hold the oil pump to the engine.4. Install bolts (4) that hold the elbow to the oil pump.5. Install the bolt and lock that hold suction bell (1) to the oil pan plate.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump (3304) or remove oil pump (3306) 1. Remove idler gear (2). Remove the bearing from the idler gear with Tool (B).2. Remove suction bell (1).3. Remove the bolt and the washer from the oil pump drive gear. 4. Remove the drive gear from the shaft with Tool (A).5. Remove the key from the pump shaft.6. Remove bolts (3) from the pump body. 7. Remove body (8), two gears (7), the keys and spacer (4) from the pump.8. Remove two shafts (5) and the gears.9. Remove bolts (6), the cover and the pressure relief valve from the body. 10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with Tool (B).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with Tool (A) and a press as follows:a. Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is 1.52 mm (.060 in) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with Tool (A) and a press as follows:a. Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump body. Make sure the joints in the bearings are at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check the condition of the relief valve. Check the condition and specifications for all the parts of the oil pump before
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101401-2142
INJECTION-PUMP ASSEMBLY