101402-9530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9530 1014029530

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Service parts 101402-9530 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8451

3. GOVERNOR 105419-2470

4. SUPPLY PUMP

105220-7170

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-9342 as _

101402-9530 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-9530 1014029530

Zexel num

Bosch num

Firm num

Name

101402-9530

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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.6 3.55 3.65

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 A

Rack position 10.2

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 66 65 67

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.6+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13 12 14

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 80 90

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2 (7)Rack difference between N = N3 and N = N4
----------
K=12 N1=1250r/min N2=800r/min N3=1250r/min N4=450r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At delivery
----------

----------
a=58deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Start By:a. remove governor **See Disassemble Governor story
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the bolts and the plate from the side of the fuel injection pump housing. 2. Install tool (A) in the fuel injection pump housing. Move the rack until tool (A) can be installed to hold the rack in the center position to remove the fuel injection pumps.3. Use tool (B) to remove bushing (1).4. Remove the O-ring seal from the fuel injection pump housing. 5. Install tool (C) on the bonnet and remove the fuel injection pump. 6. Remove spacer (2). Keep the spacers (2) from the fuel injection pumps together with identification as to their location in the pump housing.7. Perform steps 3 through 6 to remove the other fuel injection pumps. The following steps are to install the fuel injection pumps.8. Install spacer (2).9. Install tool (A). Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.10. Turn camshaft until the lobe of the camshaft is down for the pump to be installed.11. Install tool (C) on the bonnet on the fuel injection pump.12. Install the fuel injection pump in the pump housing with saw cut slot in the gear in alignment with the small pin and groove in the barrel in alignment with dowel in the pump housing.13. Put clean oil on O-ring seal and install it in the fuel injection pump housing.14. Install the bushing by hand until the bushing is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump ad put the pump in alignment again and install the bushing again.15. Install tool (B) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft).16. Install tooling (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of improper fuel injection pump installation.17. Perform Steps 1 through 9 to install the other fuel pumps18. Install the cover and gasket on the fuel injection pump housing.End By:a. install governor **See Assemble Governor storyDisassemble And Assemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
When the injection pumps are disassembled, handle the parts carefully. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not intermix the plunger of one pump in the barrel with another pump. If one part is worn, install a complete new pump assembly. Be careful when placing the plunger into the bore of the barrel.
1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2).
Do not remove the gear from