101602-2680 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022680

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2680 1016022680

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Buy INJECTION-PUMP ASSEMBLY 101602-2680 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2680 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9690

3. GOVERNOR 105401-0530

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-4821

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4320

11. Nozzle and Holder 23600-1710A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101602-2680 as INJECTION-PUMP ASSEMBLY

101603-8344 as _

Cross reference number

ZEXEL 101602-2680 1016022680

Zexel num

Bosch num

Firm num

Name

101602-2680

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 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

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

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

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

Injection quantity adjustment

Adjusting point A

Rack position 10.4

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 86 84 88

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 26.7 26.7

Boost pressure mmHg 200 200

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 98 98 108

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-1.2

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(10.4)

Boost pressure kPa 13.3 13.3 13.3

Boost pressure mmHg 100 100 100

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke
----------
K=12
----------

Speed control lever angle

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

----------
a=15deg+-5deg b=28deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

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:

Illustration 62 g02807941
Remove the plug
Remove plug (2) .
Illustration 63 g02807956
Set speed by turning adjusting screw
Adjust speed. If Ng exceeds TMI specifications, tighten the adjusting screw. If Ng is less than the specified value, loosen the adjusting screw.
Illustration 64 g02807957
Adjust the maximum-speed stopper bolt
Adjust the maximum-speed stopper bolt until the speed at the start of high-speed control is Nf.
Check that the no-load maximum speed is Ng (described in Step 1). Continue adjustment until the specified value is obtained.
Illustration 65 g02807958
Increase pump speed to make sure that the control rack position reaches Ra.
Illustration 66 g02807959
Full-load Adjustment
Illustration 67 g02807997
Install the cover and adjust full-load stopper bolt
Install cover (3) on governor using bolts and lockwashers (2). Use caution when installing the cover to make sure that the O-ring seal is in the seal groove.
Illustration 68 g02807999
Position the control lever at maximum-speed position.
Adjust full-load stopper bolt (1) to the f"ull-load fuel injection quantity" position. See TMI for the specifications (Point A).
Install cap.Control Lever Angle Measurement
Illustration 69 g02808016
Measuring control lever angle at the "full-speed" and "idling" positions.
Measuring the control lever angle at the "idling" and "full" positions.
If the angle is not as specified by TMI, replace the shifters shim. If the control lever is positioned toward the "full" position, replace the shifters shim with a thicker one. When control lever is toward the "idling" position, replace the shim with a thinner one.Check Starting Delivery
Illustration 70 g02808018
Remove measurement adapter
Remove measurement adapter (1) .
Illustration 71 g02808038
Cap must be installed to check delivery rate
Install cap (2) .
Run pump at speed specified in TMI.
Check delivery rate with specifications listed in TMI.
Stop pump rotation.
Illustration 72 g02808058
Adjusting screw for setting fuel flow
If delivery rate does not meet TMI specifications, remove cap (2), loosen lock nut, and adjust screw (3). Adjusting screw outward decreases fuel flow and inward increases fuel flow.
Install cap (2) and recheck delivery rate. Repeat Steps 2 through 6 until delivery rate is at specified value.Lockwiring Caps of Adjustment Screws
All adjustment stops (screws) that directly affect engine performance should be lockwired after adjustment. Do not readjust any stop without using the test stand can adversely affect the engine and engine performance.