101602-1501 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016021501

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-1501 1016021501

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Service parts 101602-1501 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9900

3. GOVERNOR 105402-2660

4. SUPPLY PUMP

105210-5250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-1020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5031

11. Nozzle and Holder ME016655

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

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-1040

15. NOZZLE SET

Include in #1:

101602-1501 as INJECTION-PUMP ASSEMBLY

Include in #2:

104057-3280 as _

Cross reference number

ZEXEL 101602-1501 1016021501

Zexel num

Bosch num

Firm num

Name

101602-1501

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 131424-5520

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 1-5-3-6- 2-4

Pre-stroke mm 3.5 3.45 3.55

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 9.7

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 68 67 69

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 7.5 6.2 8.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Rack limit *

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)Supplied with torque spring not set. (4)RACK LIMIT (5)Set idle sub-spring (6)Main spring setting
----------
K=12
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=24deg+-5deg

Stop lever angle

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

----------
a=26.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12.5deg
----------
a=(130deg)

Information:

Rework Procedure
This procedure is only required when utilizing the 444-2472 Bracket As or 444-2473 Bracket As, the former 222-6953 Valve Cover Bases, and the new stamped steel valve covers. Disregard if using 442-5727 Valve Cover Base.The preferred method to correct this issue is to remove the former 222-6953 Valve Cover Base and install the current 442-5727 Valve Cover Base. This valve cover base removes the need for the 444-2472 Bracket As and 444-2473 Bracket As.The alternative method is to modify the 444-2472 Bracket As or 444-2473 Bracket As to be used with the 222-6953 Valve Mechanism Cover Base and stamped steel valve cover.Note:
Illustration 1 g06088172
Bracket assemblies view
(1) 444-2472 Bracket As
(2) 444-2473 Bracket As
Illustration 2 g06088191
Side view of the bracket.
(3) Button portion
(4) Weld stud
Illustration 3 g06088192
Top view of the bracket.
The illustration above shows the location of the material that will need to be removed from the button of the bracket assemblies.
Illustration 4 g06088194
Side view of the bracket.
Illustration 5 g06088195
View of the bracket after modification.
Remove 4 mm (0.16 in) from the button on the bracket as shown in Illustration 4.
Once the additional material has been removed from the modified bracket, fit the valve cover to ensure that proper clearance has been created allowing sealing of valve cover PIP seal. Install and torque the valve cover using the appropriate procedure from the Disassembly and Assembly manual.
Illustration 6 g06088196
Impression made by bracket assemblies that contact the valve cover.
Remove the valve cover and inspect the mating surface to see if any contact marks are present as shown in Illustration 6. If contact marks are present, extra material of the button will need to be removed for clearance.