101401-9171 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019171

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9171 1014019171

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Service parts 101401-9171 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9881

3. GOVERNOR 105921-6150

4. SUPPLY PUMP 105210-3300

5. AUTOM. ADVANCE MECHANIS 105671-0091

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4871

11. Nozzle and Holder TF01 13 H50

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3450

14. NOZZLE 105017-0861

15. NOZZLE SET

Include in #1:

101401-9171 as INJECTION-PUMP ASSEMBLY

101603-2350 as _

101603-2351

Cross reference number

ZEXEL 101401-9171 1014019171

Zexel num

Bosch num

Firm num

Name

101401-9171

INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, 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 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 3.3 3.25 3.35

Beginning of injection position
Drive 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 12.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 64.6 64.1 65.1

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. 9 7 11

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(12.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 64.6 64.1 65.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1625 1625 1625

Average injection quantity mm3/st. 79.3 75.3 83.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 625 625 625

Average injection quantity mm3/st. 47.4 43.4 51.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 160

Fixing the lever *

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min 1625

Advance angle deg. 3.8 3.5 4.1

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.
----------
T1=E03
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=20deg+-5deg b=(41deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(29.5deg)+-5deg

0000001501 LEVER

CL:Center line of camshaft ST:Stop adjuster screw f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever 1. Stop lever adjustment outline (1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position. (2)Set the speed lever in the full speed position. (3)At pump speed Na, position the rack at non-injection position Ra. (4)Set the stop adjusting screw to fix the speed lever in the idling position. (5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=4.7+-0.3mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(130deg)

Information:

Start By:a. remove crankshaft rear seal and wear sleeveb. remove oil pan 1. Fasten a hoist to implement pump (1) and remove the pump (if equipped). The weight of implement pump (1) is 29 kg (75 lb). 2. Remove plates (2).3. Remove pump drives (3) (if equipped) with Tool (A) and a hoist. The weight of each pump drive is 29 kg (65 lb). 4. Remove plate (4). 5. Remove starting motor (5) and disconnect oil supply line (6) at the flywheel housing. 6. Remove engine rear supports (7). 7. Remove turbocharger oil supply line (8) and bracket (9). 8. Remove top section of turbocharger heat shield (10). 9. Remove turbocharger drain line (11) and elbow (12). 10. Remove plate (13). 11. Remove bolts (14) and the remainder of the bolts which hold bracket (15) to the engine and remove bracket (15). 12. Use Tooling (A) and fasten a hoist to flywheel housing (16). Remove the bolts that hold flywheel housing (16) in position and pull flywheel housing off the dowels and remove it. The weight of the flywheel housing is 191 kg (425 lb).13. Put the flywheel housing in the position shown. 14. Remove bolts (17) from shafts (19).
Bearings (20) can fall out of gears (18) when the gears are removed from the flywheel housing.
15. Remove gears (18) from the flywheel housing. 16. Remove shafts (19), bearing cones (22), spacers (21) and bearing cones (20) from gears (18). 17. If necessary, remove bearing cups (23) and (25), spacers (24) and the snap rings from gears (18). The bearing cups will have damage after removal. Use new parts for replacement.Install Flywheel Housing
1. Install the snap rings in the groove in idler gear (2).2. Install the spacers for bearing cups (1) in gears (2) from the side of gears (2) that have the part number. Make sure the notches in the spacers are toward the snap rings. The snap rings are not in the center of the gear bores. The spacers must be installed in the gear bores that have the longer measurement from the snap ring to the surface of the gear.3. Lower the temperature of bearing cups (1) and install them in gears (2) until they make contact with the spacers. 4. Put the flywheel housing in the position shown and install bearing cones (3). 5. Put idler gears (2) in position on the bearing cones. Make sure the side of gears (2) with the part number is toward the flywheel housing. 6. Put spacer (4) on the inner race of the bearing cone. 7. Install bearing cones (5) in the gears. 8. Install shafts (6) and the bolts to hold them.
Put the No. 1 piston at top center to make an alignment of the timing marks on the crankshaft rear gear (9) with the balancer gear (8). Failure to follow this procedure can cause damage to the engine.
9. Clean the front face of the flywheel housing and the rear face of the cylinder block. Make