101601-5380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5380 1016015380

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Service parts 101601-5380 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-2830

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0220

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-5640

15. NOZZLE SET

Include in #1:

101601-5380 as INJECTION-PUMP ASSEMBLY

106685-4130 as _

Cross reference number

ZEXEL 101601-5380 1016015380

Zexel num

Bosch num

Firm num

Name

101601-5380

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 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 44.6 48.6

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. 8 6.5 9.5

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(8.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 45.6 47.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 45.2 43.2 47.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 52 50 54

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.15

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 38 36 40

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.35

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 28 24 32

Fixing the lever *

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=A76 RAL=(R1+0.2)+0.2mm
----------

Speed control lever angle

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

----------
a=33deg+-3deg b=34deg+-5deg

Stop lever angle

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

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

1. Disconnect fuel line (1) from the fuel transfer pump. Disconnect fuel line (2) from the fuel injection pump housing. Remove line (3) from the fuel ratio control and aftercooler housing. 2. Disconnect fuel injection lines (4) from the fuel injection pump housing.
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
3. Loosen the bleed valves, and release the air pressure in the air tank. 4. Remove air line (5). Remove coolant line (6). 5. The weight of the fuel injection pump housing and governor is 57 kg (125 lb). Attach a hoist to the fuel injection pump housing, and remove bolts (7). 6. Remove the two nuts and two bolts (8) and bolt (9). Remove fuel injection pump housing and governor (10). 7. Remove O-ring seals (11) from the fuel injection pump housing.Install Fuel Injection Pump Housing And Governor
1. Attach a hoist to the fuel injection pump housing and governor (1). Be sure that the three O-ring seals are in position in the fuel injection pump housing. Install the fuel injection pump housing and governor on the timing gear housing. 2. Connect air line (2) and water line (3) to the air compressor. 3. Connect fuel injection lines (4) to fuel injection pump housing, and tighten the fuel injection line nuts to a torque of 40 7 N m (30 5 lb ft) with tool (C). 4. Connect fuel line (5) to fuel injection pump housing, and connect fuel line (6) to the fuel transfer pump. Install line (7) between the fuel ratio control and aftercooler housing. For timing of the fuel injection pump, see Install Automatic Timing Advance.End By:a. install automatic timing advance