101601-5371 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015371

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5371 1016015371

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Service parts 101601-5371 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-2781

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0580

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7570

11. Nozzle and Holder 23600-1843

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/19.6{200}

13. NOZZLE-HOLDER 105030-4160

14. NOZZLE 105015-7580

15. NOZZLE SET

Include in #1:

101601-5371 as INJECTION-PUMP ASSEMBLY

106685-4420 as _

Cross reference number

ZEXEL 101601-5371 1016015371

Zexel num

Bosch num

Firm num

Name

101601-5371

INJECTION-PUMP ASSEMBLY
14BE PE6A PE

101601-5371
101601-5372

220005941A HINO

INJECTION-PUMP ASSEMBLY
A * K 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 9.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.9 55.9 59.9

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 7.8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 5.3 3.8 6.8

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(9.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.9 56.9 58.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.6)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 63.9 59.9 67.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 40.3 36.3 44.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1(9.6)

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 63.7 59.7 67.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.45

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 39.9 35.9 43.9

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position 14.5+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 108 108 118

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1330--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1280

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4.5 4.2 4.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C02
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Speed control lever angle

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

----------
a=37deg+-5deg b=(40deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

0000001501 LEVER

(E): fix 1. Air cylinder adjustment (1)With the speed lever in the idling position, temporarily set the clearance between speed lever (A) and set bolt (B) at approximately L. (2)Set pump speed to N1 and apply pressure P1 to the air cylinder (C). (3)Gradually push out set bolt (B) so that the rack position is R1 at pump speed N2. Then tighten nut (D). (4)Apply air pressure several times. (5)Confirm that the lever returns to the idling position at pressure P2. (6)Also, confirm that the rack position is R1 at air pressure P = P1.
----------
L=(1.4)mm N1=475r/min P1=392+98kpa(4+1kgf/cm2) N2=475r/min R1=7.3+-0.1mm P2=0kpa(0kgf/cm2)
----------

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:

1. Remove the two bolts, and remove the fuel ratio control from the governor. Remove O-ring seal (1) from the fuel ratio control. 2. Put tooling (A) in a vise as shown so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in tooling (A). Remove cover (2) and the O-ring from fuel ratio control.
There is spring force behind cover (3). Hold cover (3) in position, and slowly remove the bolts that hold it to release the spring force.
3. Remove cover (3) from housing (4). 4. Remove spring (7), washer (5), and diaphragm (8) from retainer (6). Remove retainer (6) from housing (9). 5. Remove nut (14) from extension (13), and remove the extension from retainer (6). Remove valve (10), spring (11) and O-ring seal (12) from the extension. 6. Remove spring (16), retainer (15) and spring (17) from the housing. 7. Remove piston assembly (18) from the housing. 8. Use tooling (B), and remove snap ring (19) and the wave washers from valve assembly (20). Remove piston assembly (21) from the valve assembly.9. Remove seal (22) from piston (21). 10. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.Assemble Fuel Ratio Control
1. If valve (1) and stem (2) are loosened or partially unscrewed, the valve assembly should be replaced with new. 2. Put seal (4) on piston (3), and put piston (3) on valve assembly (5). 3. Put two wave washers in position on valve (5), and use tooling (A) to install the snap ring on the valve assembly. 4. Place housing (7) on tooling (B), and put tooling (C) into the bore of the housing. Lubricate tooling (C) with clean engine oil.5. Put a small amount of clean oil on the seal of the piston assembly, and push piston assembly (6) into position with a smooth swift motion. 6. Place spring (8) and retainer and spring (9) in position in housing (7). 7. Put O-ring seal (12) on extension (13). Put spring (11) and valve (10) in position on the extension.8. Lubricate O-ring seal (12) with clean engine oil. Install extension (13) in retainer (14). Install nut (15). 9. Put diaphragm (18), washer (17) and spring (16) in position on retainer (14). Install retainer (14) in housing (7). 10. Hold retainer (14) in position, and install cover (19) on the housing. Install the bolts that hold the cover, and tighten them to a torque of 9 3 N m (7 2 lb ft). 11. Inspect the O-ring for cover (20). Replace the O-ring if worn or broken. Install the cover. 12. Put O-ring seal (21) in position on the fuel ratio control.13. Put the fuel ratio control in position on the governor. Make sure the flange on the end of the fuel ratio control is behind the groove (slot) in the lever. Install the bolts that hold the fuel ratio control in position. See the Testing