101601-5201 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015201

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5201 1016015201

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Service parts 101601-5201 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-1791

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0340

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder 23600-1593A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-5640

15. NOZZLE SET

Include in #1:

101601-5201 as INJECTION-PUMP ASSEMBLY

106682-4730 as _

Cross reference number

ZEXEL 101601-5201 1016015201

Zexel num

Bosch num

Firm num

Name

101601-5201

INJECTION-PUMP ASSEMBLY
14BE PE6A 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 131424-5720

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 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 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 9.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 52.4 50.4 54.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 6.8 5.3 8.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 52.4 51.4 53.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 50.2 46.2 54.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.35

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 36.5 32.5 40.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 53.1 49.1 57.1

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.2

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 29.2 25.2 33.2

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 99 99 109

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4.5 4.2 4.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C09
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-5deg b=35deg+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (After setting, apply red paint.) (2)-
----------

----------
a=20deg+-5deg b=(28deg)+-5deg

0000001501 LEVER

(N) Engine normal (pump normal) (S) Engine stop (A) stopper screw (B) Stop direction (perpendicular) Stop lever adjusting procedure (1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above. (2)With the speed lever at Full and the pump speed at Na (specified speed), temporarily set the stopper screw (A) at the rack position Ra. (3)Turn the stopper screw (A) Rb in the stop direction (Nb turns) and set it. Measure the rack position. (Rack position = approx. Rc) (4)After setting, confirm non-injection with the speed lever at idle and pump speed at Nc. (5)After adjustment, apply red paint.
----------
Na=1600r/min Ra=5.1mm Rb=1.5mm Nb=1.5 Rc=3.1mm Nc=250r/min
----------
ra=37mm a=20deg+-5deg b=(28deg)+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

Start By:a. remove flywheel
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal with tool (A). 2. Install tool (C) as shown.3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve in loose.4. Remove tool (C) and the wear sleeve by hand. The following steps are for the installation of the crankshaft rear seal and wear sleeve. 5. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows:a. Put locator (1) in position on the crankshaft and install the three bolts that hold it in place.b. Put clean engine oil on the seal lip of seal (6) and on the outside diameter of wear sleeve (2).c. Install seal (6) on wear sleeve (2) from the end of the wear sleeve that has the bevel on the outside diameter. Make sure the lip of the seal is toward the inside of the engine and the bevel that is on the outside diameter of the wear sleeve is toward the outside of the engine when installed.d. Use 6V1541 Quick Cure Primer to clean the outside diameter of the crankshaft flange (3) and the inside diameter of wear sleeve (2).e. Put 9S3265 Retaining Compound on the outside diameter of crankshaft flange (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.f. Put wear sleeve (2) with seal (6) on locator (1). Put installer (4) on locator (1) and install nut (5). Put lubrication on the face of the washer and the nut.g. Tighten nut (5) until installer (4) comes in contact with locator (1).h. Remove tooling (A) and check the wear sleeve and seal for correct installation.End By:a. install flywheel