101402-9533 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014029533

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-9533 1014029533

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Service parts 101402-9533 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8770

3. GOVERNOR 105419-2472

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:

101402-9451 as _

101402-9533 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101402-9533 1014029533

Zexel num

Bosch num

Firm num

Name

101402-9533

YANMAR

INJECTION-PUMP ASSEMBLY
4TNE98 * 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:

1. Turn the fuel supply line valve to the "OFF" position.2. Remove tube assembly (2) and tube assembly (4).3. Remove bolts (1) and (5). Remove fuel transfer pump (3). Remove the O-ring seal from the fuel transfer pump if necessary. Assemble in reverse order.Disassemble And Assemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove bolts (2) and cover (1) from fuel transfer pump housing (11). Remove seals (5) and (6), and valve (4).2. Remove spring (3), washer (7), valve (13), seal (8), sleeve (9), and piston (10). Remove seal (19).3. Remove seal (14) and guide and tappet assembly (12).4. Remove screw (17), cover (18) and seal (16). Remove valve assembly (15).5. To assemble fuel transfer pump, install valve assembly (15) in the fuel transfer pump housing. Lubricate seal (16) lightly and install it with cover (18) and screw (17).
The tappet and guide of the guide and tappet assembly must be serviced as a unit.
6. Install seal (14) and guide and tappet assembly (12) in the fuel transfer pump housing.7. Install seal (19) on sleeve (9). Install piston (10), sleeve (9), seal (8), valve (13), and washer (7). Install spring (3).8. Install seal (5), seal (6), and valve (4). Install cover (1) and bolts (2).End By:a. install fuel transfer pump