101600-3050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016003050

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101600-3050 1016003050

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Cross reference number

ZEXEL 101600-3050 1016003050

Zexel num

Bosch num

Firm num

Name

101600-3050

INJECTION-PUMP ASSEMBLY
14BF PE6AD 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 134424-4120

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 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 160.5 159.5 161.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 133 133

Boost pressure mmHg 1000 1000

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.5+-0.5

Pump speed r/min 460 460 460

Average injection quantity mm3/st. 14.5 12.5 16.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-1.6

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(10.6)

Boost pressure kPa 120 113.3 126.7

Boost pressure mmHg 900 850 950

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)When the hydraulic cylinder is OFF (6)When hydraulic cylinder ON: P1 (7)Boost compensator stroke: BCL (8)Main spring setting (9)Set idle sub-spring
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K=13 P1=(127+-10kPa{1.3+-0.1kgf/cm2}) BCL=1.6+-0.1mm
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Speed control lever angle

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

----------
a=0deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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----------
a=25deg+-5deg b=53deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (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) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
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T1=7.16~9.12N-m(0.73~0.93kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m) T3=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=7deg bb=0deg
----------
a=54deg42min+-3deg b=3deg30min+-30min

Information:

Illustration 7 g06347860
Injector male spade terminals
There are two options to build injector adapter harness for C3.3.If available, use the injector connector removed from C3.3 harness. Cut both 100 mm wires from the connector and attach bullet terminals that fit in the injector adapter harness C3.8 terminal from injector test kit.If no harness is available, build a harness with the following. Two female spade terminals for injector male spade terminal, two 16 gauge 100 mm wires, and two bullet terminals for injector adapter harness C3.8 terminal.
Illustration 8 g06345429
Injector adapter harness C2.4
Illustration 9 g06346223
Injector adapter harness C3.8
Illustration 10 g06346237
Injector male spade terminals
There are two options to build injector adapter harness for C2.4.If available, use the injector connector removed from C2.4 harness. Cut both 100 mm wires from the connector and attach bullet terminals that fit in the injector adapter harness C3.8 terminal from injector test kit.If no harness is available, build a harness with the following. Two female spade terminals for injector male spade terminal, two 16 gauge 100 mm wires, and two bullet terminals for injector adapter harness C3.8 terminal.Injector Test Set-up
Illustration 11 g06346391
Mounted nozzle test group
Find a suitable stable and surface to either mount or place the nozzle test group. Fill fuel container with #1 diesel and install high-pressure hose assembly. Use adaptors, if needed, based on nozzle tester. Tighten the fuel line adapter to (25 ft lbs). Install the fuel line adapter and tighten to (25 ft lbs) to allow connection to the injector.
Illustration 12 g06346423
Injector holder assembly
Take the injector test kit and remove all parts to assemble, as shown above. Take the injector holder and the clear fuel shield with screws from the kit and remove the screws using a 3mm alan wrench. Assemble the parts so the clear fuel shield with screws is on the bottom. While, the mounted injector holder is on top with the screws removed from before.
Illustration 13 g06346719
Fuel collector and injector holder
Place injector holder onto a fuel collector or another container to capture the injection spray.
Illustration 14 g06346839
Injector setup and harness connection
Install the injector that is needing to be tested into the opening at the top of injector holder. Attach the return fuel drain hose and run the drain hose to another fuel collector. Make the harness connection using the correct adapter for the C2.4, C3.3, and C3.8 engines. Connect the injector pulse tool and the injector adapter harness to the injector.
Illustration 15 g06346868
Complete setup of nozzle tester and injector test kit
Once injector test kit and nozzle test group are set up, connect fuel line adaptor on the high-pressure hose assembly to the injector, leave connection loose. Actuate the lever on the nozzle test group until fuel drips from connection allowing air to purge from setup. Tighten fuel line adaptor at injector to (25 ft lbs).Injector Test Procedure
Illustration 16 g06346881
Mounted nozzle test group (close-up)
Inspect the injector for any leaks. Using the lever on the nozzle tester group, build injection fuel pressure to (5000 psi). Turn the locking valve to insure there is no leakage back through the tester.
Let the nozzle test