101401-7395 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014017395

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-7395 1014017395

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Service parts 101401-7395 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8490

3. GOVERNOR 105932-2031

4. SUPPLY PUMP 105210-6170

5. AUTOM. ADVANCE MECHANIS 105676-8050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6381

11. Nozzle and Holder 8-97144-997-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE 105017-2220

15. NOZZLE SET

Include in #1:

101401-7395 as INJECTION-PUMP ASSEMBLY

106682-3001 as _

Cross reference number

ZEXEL 101401-7395 1014017395

Zexel num

Bosch num

Firm num

Name

101401-7395

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 134424-3920

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 12.5

Pump speed r/min 930 930 930

Average injection quantity mm3/st. 70 68.4 71.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H`

Rack position 9.8+-0.5

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -7 7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point H

Rack position 9.7+-0.5

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 9.5 8.2 10.8

Fixing the rack *

Injection quantity adjustment_04

Adjusting point A

Rack position R1(12.5)

Pump speed r/min 930 930 930

Average injection quantity mm3/st. 70 69 71

Basic *

Fixing the lever *

Injection quantity adjustment_05

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 91.5 87.5 95.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point C

Rack position R1-0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 48.6 44.6 52.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point D

Rack position R1+0.4

Pump speed r/min 1240 1240 1240

Average injection quantity mm3/st. 82 78 86

Fixing the lever *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min 1550

Remarks
Measure the actual advance angle.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 6 6 6

Remarks
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=M59
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.7)mm bb=330r/min
----------
a=36deg+-5deg b=33deg+-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

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=430r/min Ra=9.5+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

0000001601 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=930r/min Ra=R1(12.5)mm Vist=2.86+-0.28V
----------

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)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=8.5deg
----------
a=(60deg) b=(85deg)

Information:

Start By:a. remove flywheel The crankshaft rear seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made. 1. Make at least three holes in seal (1) with a hammer and a sharp punch.2. Use Tool (A) to remove seal (1). 3. Install Tool (C) in the seal bore.4. Install Tool (B) between Tool (C) and wear sleeve (2). Turn Tool (B) until the Tool makes a dent (crease) in wear sleeve (2). Do this in three or more places until the wear sleeve is loose.5. Remove Tools (B) and (C), and remove wear sleeve (2) from the crankshaft.Install Crankshaft Rear Seal & Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
Typical Example1. Install the rear crankshaft seal and wear sleeve with Tool (D). Use the procedures which follow: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.b. Install locator (3) and the bolts on crankshaft (4).c. The seal and wear sleeve must be installed dry. Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong side of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (7) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until installer (5) makes contact with locator (3).h. Remove Tool (D) from the crankshaft seal and wear sleeve. Tool (D) will install the seal and wear sleeve to the correct depth on the crankshaft.End By:a. install flywheel