Information injection-pump assembly
ZEXEL
101495-3530
1014953530

Rating:
Service parts 101495-3530 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101495-3530
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-7320
as _
Cross reference number
ZEXEL
101495-3530
1014953530
Zexel num
Bosch num
Firm num
Name
101495-3530
INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE
14BC PE4A,5A, PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131425-1420
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-4-3
Pre-stroke
mm
3.2
3.15
3.25
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
80.5
79.5
81.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
45.3
45.3
Boost pressure
mmHg
340
340
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.3+-0.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
13
12
14
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
E
Rack position
10.6++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
63
58
68
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
750
750
750
Rack position
R2-1.55
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
750
750
750
Rack position
R2-1.15
Boost pressure
kPa
13.3
12
14.6
Boost pressure
mmHg
100
90
110
Boost compensator adjustment_03
Pump speed
r/min
750
750
750
Rack position
R2(10.4)
Boost pressure
kPa
32
32
32
Boost pressure
mmHg
240
240
240
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
(4)Set idle sub-spring
(5)Rack difference between N = N1 and N = N2
----------
K=10 BCL=1.55+-0.1mm N1=1100r/min N2=750r/min
----------
----------
K=10 BCL=1.55+-0.1mm N1=1100r/min N2=750r/min
----------
Speed control lever angle

F:Full speed
I:Idle
S:Stop
(1)Use hole at R = aa (middle hole)
(2)Stopper bolt setting
----------
aa=80mm
----------
a=3deg+-3deg b=35deg+-3deg c=27deg+-5deg
----------
aa=80mm
----------
a=3deg+-3deg b=35deg+-3deg c=27deg+-5deg
0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure
(A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads.
(B): Specified torque
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
0000001601 I/P WITH LOAD PLUNGER ADJ
Load plunger-equipped pump adjustment
1. Adjust the variation between cylinders and the injection quantity.
2. At Full point A, adjust the pre-stroke to the specified value.
3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------
----------
----------
----------
Timing setting

(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)B.T.D.C.: aa
----------
aa=7.4deg
----------
a=58deg+-3deg b=2deg+-30min
----------
aa=7.4deg
----------
a=58deg+-3deg b=2deg+-30min
Information:
Safety is basically common sense. There are standard safety rules but each situation has its own peculiarities which cannot always be covered by rules. Your experience and common sense will be your best guide to safety. Be ever watchful for safety hazards and correct deficiencies promptly.Use the following safety precautions as a general guide to safe driving and maintenance practice. It is your responsibility to practice and promote safety. 1. Obey the rules of the road.2. Never adjust or repair engine or vehicle while it is in operation.3. Remove all tools and electrical cords before starting engine or operating vehicle.4. Keep work area clean.5. Store oily rags in containers.6. Store flammable liquids in a safe place away from the work area.7. Do not smoke around batteries. Hydrogen gas generated by charging is explosive. Keep batteries in a well ventilated area.8. Observe NO SMOKING signs.9. Do not wear loose clothing.10. Never operate an engine except in a well ventilated area.11. When cleaning with air do not exceed 30 PSI (2, 1 kg/cm2). Servicing cab-over truck engines require additional safety precautions as follows: Before Tilting Cab:1. Check clearance above and in front of truck cab.2. Keep tool chests and workbenches away from front of cab.3. Inspect sleeper and cab interior for loose luggage, tools and liquid containers which could fall forward.4. Check "Buddy" or "Jump" seats on right side of cab to be sure they are secured in place. While Tilting Cab1. Be sure the governor, transmission and clutch linkage do not interfere with the cab.2. Check position of steering shaft U-joint to prevent binding.
BEFORE TILTING CAB CHECK AREA FOR SUFFICIENT CLEARANCE AND OBSTRUCTIONS3. Never work under a partially tilted cab, unless it is properly secured.4. When cab is tilted past the over-center position, use cables or chains to prevent it from falling. Do not rely on cab hydraulic lift mechanism to retain or break the fall of the cab in any position beyond the over-center point. While Cab is Tilted1. If it's necessary to open a door, take care to avoid damage to door hinges and/or window glass. While Lowering Cab1. Watch all governor, steering, clutch and transmission linkage. Bellcranks may turn over center, shift levers jam against bottom of cab and some models of clutch links separate when tilting cab. These clutch linkage components can miss their mating part when the cab is lowered.2. Be sure mating ends of exhaust and air cleaner inlet pipes align properly.3. Be sure cab lowers properly on mounting and locating pins. Twisted or misaligned cabs may miss locating pins and cab latch will not secure cab in locked position.4. Lock cab latching mechanism when cab is all the way down.
BEFORE TILTING CAB CHECK AREA FOR SUFFICIENT CLEARANCE AND OBSTRUCTIONS3. Never work under a partially tilted cab, unless it is properly secured.4. When cab is tilted past the over-center position, use cables or chains to prevent it from falling. Do not rely on cab hydraulic lift mechanism to retain or break the fall of the cab in any position beyond the over-center point. While Cab is Tilted1. If it's necessary to open a door, take care to avoid damage to door hinges and/or window glass. While Lowering Cab1. Watch all governor, steering, clutch and transmission linkage. Bellcranks may turn over center, shift levers jam against bottom of cab and some models of clutch links separate when tilting cab. These clutch linkage components can miss their mating part when the cab is lowered.2. Be sure mating ends of exhaust and air cleaner inlet pipes align properly.3. Be sure cab lowers properly on mounting and locating pins. Twisted or misaligned cabs may miss locating pins and cab latch will not secure cab in locked position.4. Lock cab latching mechanism when cab is all the way down.
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Komatsu
101495-3530
INJECTION-PUMP ASSEMBLY