101602-2760 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022760

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2760 1016022760

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Service parts 101602-2760 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9940

3. GOVERNOR 105400-8310

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-4821

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4230

11. Nozzle and Holder 23600-1580A

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

13. NOZZLE-HOLDER 105041-5030

14. NOZZLE 105015-5160

15. NOZZLE SET

Include in #1:

101602-2760 as INJECTION-PUMP ASSEMBLY

107692-1270 as _

Cross reference number

ZEXEL 101602-2760 1016022760

Zexel num

Bosch num

Firm num

Name

101602-2760

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 3.05 3.15

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 9.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 45.3 43.3 47.3

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.9+-0.5

Pump speed r/min 460 460 460

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

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. 63 63 73

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)RACK LIMIT (4)Main spring setting (5)Set idle sub-spring
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=5deg+-5deg b=18deg+-5deg c=0deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At delivery (2)Rack position aa or less, pump speed bb
----------
aa=7mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-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:

Locations and Methods for Measuring the Pressures of the Low-Pressure Fuel System
Illustration 1 g03325145
Front View of a typical fuel inlet lines group (A) Fuel inlet port (B) Test port for the fuel supply pressure (C) Fuel transfer pump (D) Test port location for system pressureInlet Fuel Pressure to the Transfer Pump (set at rated speed and load)
Install a 6V-3965 Fitting into Port (B) using a 214-7568 O-Ring Seal Note: The inlet pressure to the fuel transfer pump can affect overall system pressure. All filters or water separators before the transfer pump must be new and clean prior to setting the system pressure at the fuel pressure regulator.
Connect the 6V-7830 Pressure Gauge to the fitting installed in the previous step.
Set the engine to rated speed and load. Record the fuel pressure, and refer to the specifications above.Primary and Secondary Fuel Filter Differential Pressure
Primary and secondary fuel filter differential pressures are determined by the pressures from both sides of the fuel filters. This measurement will monitor fuel filter cleanliness and determine when the fuel filters require changing. Filter replacement will vary depending on fuel quality. Fuel quality can change with each shipment of fuel so monitoring the filter differential is necessary to obtain maximum filter life.Too high of a differential can cause air bubbles in the fuel system and if not corrected will lead to poor performance and injector damage. After the measurements are taken, refer to the specification above for the maximum allowable differential pressure.Primary filters or water separators should be properly sized to meet the flow requirements of the engine or engines as well as fuel being returned to the tank. Reference Table 4 for the flow requirements.
Table 4
3600 Engine Fuel Flow
Engine Model Rated Speed (rpm) Fuel Flow to Engine Fuel Flow from Engine Fuel Heat Rejection
3606 1000
41.5 L/min (11 US gpm)
32.4 L/min (8.6 US gpm)
12.5 kW (712 Btu/min)
900
38 L/min (10 US gpm)
30.0 L/min (7.9 US gpm)
11.0 kW (626 Btu/min)
750
31.5 L/min (8.3 US gpm)
24.5 L/min (6.5 US gpm)
10.5 kW (598 Btu/min)
720
30 L/min (7.9 US gpm)
23.6 L/min (6.2 US gpm)
10.0 kW (567 Btu/min)
3608 1000
41.5 L/min (11 US gpm)
30.0 L/min (7.9 US gpm)
16.7 kW (951 Btu/min)
900
38 L/min (10 US gpm)
27.6 L/min (7.3 US gpm)
14.6 kW (831 Btu/min)
750
31.5 L/min (8.3 US gpm)
22.6 L/min (6.0 US gpm)
14.0 kW (797 Btu/min)
720
30 L/min (7.9 US gpm)
21.4 L/min (5.6 US gpm)
13.3 kW (757 Btu/min)
3612 1000
78.5 L/min (20.7 US gpm)
60.1 L/min (15.9 US gpm)
25.0 kW (1423 Btu/min)
900
72 L/min (19 US gpm)
55.4 L/min (14.6 US gpm)
22.0 kW (1252 Btu/min)
750
61.2 L/min (16.2 US gpm)
47.3