101482-9350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829350

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9350 1014829350

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Cross reference number

ZEXEL 101482-9350 1014829350

Zexel num

Bosch num

Firm num

Name

101482-9350

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 2.8 2.75 2.85

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 9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 51 50 52

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 10.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 45 45 55

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
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K=9 N1=1200r/min N2=600r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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----------
a=(21deg)+-5deg b=(6deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
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----------
a=7deg+-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=(50deg)

Information:

Fuel Injection Nozzles
Disassembly of Fuel Injection Nozzles
Inspection of Fuel Injection Nozzles
Check each fuel injection nozzle for the following, and if defects are found, repair or replace the fuel injection nozzle.(1) Inspection of injection start pressure(a) Install each fuel injection nozzle on the nozzle tester, and move the handle up and down to release air.(b) Operate the handle of the tester at a rate of about 1 stroke per second, and read the indication on the pressure gage. The indication rises slowly, and the indicator oscillates during spraying. To obtain the injection start pressure value, read the indication when the indicator starts to oscillate.
Inspection of fuel injection nozzle valve opening(c) If the injection start pressure deviates significantly from the standard value, disassemble the fuel injection nozzle, and make an adjustment by changing the washer thickness. 0.1 mm [0.0039 in.] thickness of shims will change the injection pressure 0.98 Mpa (10 kgf/cm2 [142 psi]. The shims are available in 10 different thickness from 1.25 to 1.70 mm [0.0492 to 0.0669 in.] increment of 0.05 mm [0.0020 in.]
Never tap the tip of the nozzle tip when removing the nozzle tip.
Replacement of fuel injection nozzle tip(2) Inspection of fuel injection nozzle spray pattern(a) When inspecting each fuel injection nozzle with the nozzle tester, also check the nozzle for clogs, spray pattern and leakage.(b) Make sure that the fuel is sprayed straight from the nozzle when the handle of the tester is operated at a rate of about 1 stroke per second.
Inspection of spray pattern of fuel injection nozzle(3) Cleaning and replacement of faulty nozzles(a) Loosen the nozzle retaining nut, remove the nozzle tip, and clean the needle valve and body.
Never tap the tip of the nozzle tip when removing the nozzle tip.
(b) Use a fresh cleaning solution to clean the needle valve and body. After cleaning, assemble the needle valve and body in clean diesel fuel. The needle valve and body are precision finished. Handle them carefully, and do not change the combination of parts.
Cleaning of fuel injection nozzle tip(c) Tighten the nozzle retaining nut on the nozzle tip to the specified torque.(d) If the spray pattern is still not acceptable after adjustment and cleaning, replace the nozzle tip. (a) Never touch the sliding surface of the needle valve.(b) When installing a new nozzle tip, remove the seal film (synthetic resin film), and slide needle valve in the nozzle in a fresh cleaning solution to remove anti-rust oil coating thoroughly from the new nozzleReassembly of Fuel Injection Nozzles