101495-3530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953530


 

Information injection-pump assembly

ZEXEL 101495-3530 1014953530
101495-3530 INJECTION-PUMP ASSEMBLY
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Service parts 101495-3530 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-4120
3. GOVERNOR 105401-1440
4. SUPPLY PUMP 105220-5960
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105119-4160
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-4450
14. NOZZLE 105017-3630
15. NOZZLE SET

Include in #1:

101495-3530 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101495-3530 1014953530


Zexel num
Bosch num
Firm num
Name
101495-3530 
 
   
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   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
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
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.
 
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

Test data 101495-3530
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
----------

Speed control lever angle

Test data 101495-3530
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

0000001501 TAMPER PROOF

Test data 101495-3530
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)
----------

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

Test data 101495-3530
(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




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.

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