Information injection-pump assembly
ZEXEL
101401-4262
1014014262
Rating:
Service parts 101401-4262 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97114-015-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-4262
1014014262
Zexel num
Bosch num
Firm num
Name
101401-4262
INJECTION-PUMP ASSEMBLY
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
131424-4920
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
60.9
59.3
62.5
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.
10
8.7
11.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12)
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
60.9
59.9
61.9
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.6
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
83.7
79.7
87.7
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
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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.
----------
T1=G98
----------
----------
T1=G98
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=41deg+-5deg b=37eg+-3deg
----------
----------
a=41deg+-5deg b=37eg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
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=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
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
----------
a=(60deg) b=(85deg)
----------
aa=11deg
----------
a=(60deg) b=(85deg)
Information:
Start By:a. remove radiatorb. remove hydraulic pumpc. remove crankshaft pulleyd. remove alternatore. remove intake manifoldf. remove starting motorg. remove oil filterh. remove transmission
All wires, hoses, lines and linkage that is disconnected must be tied or wired out of the way to prevent damage when removing engine.
1. Identify and disconnect all electrical connections to the engine. Disconnect hydraulic lines and cab heater hoses. Disconnect all fuel lines and throttle controls. Tie or wire all wires, hoses, lines and linkage out of the way for engine removal.2. Remove front and rear engine mount bolts (1). 3. With the forks of a lift truck positioned together, position forks centered over the engine as illustrated. Install tooling (A) and then run a chain through the existing engine lifting eyes and tooling (A) as illustrated. Raise engine up slightly and start to remove engine. 4. With the engine part of the way out, remove four bolts (2) and remove rear mount bracket (3). Repeat step for the other rear mount bracket. With both rear mount brackets removed, finish removing engine. Weight of the engine is 340 Kg (750 lbs.). At the time of installation, tighten front mount bolts to a torque of 370 50 N m (270 37 lb.ft.) and rear mount bolts to a torque of 100 15 N m (75 11 lb.ft.). Install in the reverse order.End By:a. install transmissionb. install oil filterc. install starting motord. install intake manifolde. install alternatorf. install crankshaft pulleyg. install hydraulic pumph. install radiator
All wires, hoses, lines and linkage that is disconnected must be tied or wired out of the way to prevent damage when removing engine.
1. Identify and disconnect all electrical connections to the engine. Disconnect hydraulic lines and cab heater hoses. Disconnect all fuel lines and throttle controls. Tie or wire all wires, hoses, lines and linkage out of the way for engine removal.2. Remove front and rear engine mount bolts (1). 3. With the forks of a lift truck positioned together, position forks centered over the engine as illustrated. Install tooling (A) and then run a chain through the existing engine lifting eyes and tooling (A) as illustrated. Raise engine up slightly and start to remove engine. 4. With the engine part of the way out, remove four bolts (2) and remove rear mount bracket (3). Repeat step for the other rear mount bracket. With both rear mount brackets removed, finish removing engine. Weight of the engine is 340 Kg (750 lbs.). At the time of installation, tighten front mount bolts to a torque of 370 50 N m (270 37 lb.ft.) and rear mount bolts to a torque of 100 15 N m (75 11 lb.ft.). Install in the reverse order.End By:a. install transmissionb. install oil filterc. install starting motord. install intake manifolde. install alternatorf. install crankshaft pulleyg. install hydraulic pumph. install radiator
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101401-4262
INJECTION-PUMP ASSEMBLY