101401-4230 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014230

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-4230 1014014230

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Cross reference number

ZEXEL 101401-4230 1014014230

Zexel num

Bosch num

Firm num

Name

101401-4230

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 134424-3920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 4.1 4.05 4.15

Rack position
Point A R=A

Beginning of injection position
Governor 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 11.8

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 74.6 73 76.2

Max. variation between cylinders % 0 -2.5 2.5

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 325 325 325

Average injection quantity mm3/st. 8.7 7.4 10

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.8)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 74.6 73.6 75.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 93.7 89.7 97.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 79 79 111

Fixing the lever *

Timer adjustment

Pump speed r/min 1375--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.3 2.8 3.8

Timer adjustment_04

Pump speed r/min 1600--

Advance angle deg. 5 4.5 5.5

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.
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T1=G31
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=41deg+-5deg b=(38deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
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aa=64mm
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a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=500r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

0000001601 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
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N1=1100r/min Ra=9.2+-0.1mm
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Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)Pump bracket check hole position. (5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (6)B.T.D.C.: aa
----------
aa=11deg
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a=(60deg) b=(85deg)

Information:

Introduction
Tools are now available for the 6V4830 Fixture Group for removal and replacement of tappet springs on 3500 Unit Injectors.
Type 2 Fuel Injector. (1) Spring. (2) Rack Bar.
(3) 6V4830 Fixture Group. (4) 4C9279 Plate Assembly.Use fixture group (3) and plate assembly (4) along with the procedure in this instruction to remove and install tappet springs on injectors.Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Removal and Installation of Fuel Injector Tappet Springs
Take care not to damage, drop, or jar the internal parts of the injector. Injector parts must be clean when reassembled. Place a light coating of clean diesel fuel, kerosene, or calibration fluid on the moving internal components during assembly.
* Clean the outside of the injector before disassembly. Install good O-ring seals on the injector and then install a 6V4172 Cleaning Sleeve. Wash the outside of the injector with solvents and a brush. Dry with pressure air.
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
1. Remove existing plate and secure plate assembly (4) to fixture group (3).2. Remove O-ring seals from the injector prior to placing injector into fixture.3. Place injector into fixture with spring up as shown. Rack bar (2) on injector is to be extended out so that it is locked into position by two pins on plate assembly (4). 4. Using the handle of the fixture group, compress injector spring (tappet) (5) so that lock pin (6) can be pushed IN to release the tappet assembly from the injector body. 5. Remove tappet assembly from the injector body. Remove and discard old spring. Place the injector plunger on a soft clean cloth to avoid handling the plunger. Excessive handling will remove the fuel on the plunger and may result in corroding the plunger if it is left out for an extended period of time.6. Install new spring on injector body. 7. Locate the punched dot (.)(7) on the top end of the gear after it is pulled out of the body. Using a yellow magic marker, paint the whole length of the tooth that is 180° opposite the punched dot.
Injector Assembly (shown without spring).8. As the tappet/plunger assembly is inserted into the body, the yellow colored tooth on the gear should be visible in the center of the slot for the tappet lock pin.
Injector Assembly (shown without spring). 9. With the colored tooth visible in the slot of the injector body, a pin or long narrow screw driver is needed to position the gear to engage rack and pinion teeth after which the tappet assembly will drop into place.10. Using the 6V4830 Fixture Group, apply pressure on tappet (5) to compress the spring so the pin pops out and locks the tappet assembly in place.11. Remove the injector from the fixture. Push and pull the