101401-2240 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012240

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-2240 1014012240

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Service parts 101401-2240 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9471

3. GOVERNOR 105921-4100

4. SUPPLY PUMP 105220-5540

5. AUTOM. ADVANCE MECHANIS 105676-0450

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5060

11. Nozzle and Holder 23600-1981

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

13. NOZZLE-HOLDER 105041-5100

14. NOZZLE 105015-7630

15. NOZZLE SET

Include in #1:

101401-2240 as INJECTION-PUMP ASSEMBLY

107691-3121 as _

Cross reference number

ZEXEL 101401-2240 1014012240

Zexel num

Bosch num

Firm num

Name

101401-2240

INJECTION-PUMP ASSEMBLY
14BD PE4AD PE

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 4.4 4.37 4.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 11.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 98.3 96.3 100.3

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 9.2+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 21 19.5 22.5

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(11.9)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 98.3 97.3 99.3

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 99.7 95.7 103.7

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-1)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 73.8 69.8 77.8

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_06

Adjusting point D

Rack position (R1-0.75 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 81.9 77.9 85.9

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_07

Adjusting point E

Rack position -

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 55.9 51.9 59.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_08

Adjusting point F

Rack position R2-0.9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 48 44 52

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_09

Adjusting point G

Rack position R1+0.15

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 100.9 96.9 104.9

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_10

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110 120

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R2-0.9

Boost pressure kPa 6.7 6.7 9.4

Boost pressure mmHg 50 50 70

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R2(R1-1)

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Timer adjustment

Pump speed r/min 1350--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 3.5 3.2 3.8

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 (4)Boost compensator stroke: BCL
----------
T1=D36 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=34deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=35deg+-5deg b=(40deg)+-5deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)Perform after governor adjustment (torque cam phase adjustment). (2)Increase the full rack position to aa using the load lever. (3)At N = N1, push in screw (A) until Ra. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is Rb. (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
aa=(1)mm N1=1600r/min Ra=R1+0.35mm Rb=R1+0.35mm
----------
T=4.9~7N-m(0.5~0.7Kgf-m)

0000001601 ACTUATOR

(a) Screw (B) Nut (c) set bolt (d) control lever 1. Actuator adjustment procedure (1)Position the control lever (d) in the idling position. (2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator. (5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0. (7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=10.1~10.4mm P1=66.7kPa(500mmHg) N1=325r/min N2=325r/min
----------

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)

Information:

Start By:a. remove valve covers Call out (1) and (2) are not used in this removal procedure. Call outs begin with number (3). 1. Remove bolts (3) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (4).
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
2. Use Tool (A) and a 7/8 5P0328 Crow Foot ( in) to loosen the fuel injection line nut at the nozzle end. 3. Use Tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 4. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.5. Remove rocker shaft assemblies (10). 6. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 7. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies & Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 1/31/2 20 to 30 degrees ( to of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position and tighten the locknut to a torque of 30 4 N m (22 3 lb ft). Install the original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put clean engine oil on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb ft). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb ft). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb ft).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque 40 7 N m (30 5 lb ft) with Tool (A).
Do not let the tops of the fuel nozzles turn when the fuel