101603-2430 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032430

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2430 1016032430

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Buy INJECTION-PUMP ASSEMBLY 101603-2430 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2430 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5430

3. GOVERNOR 105401-0980

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105672-0470

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4270

11. Nozzle and Holder 23600-2820A

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

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105025-0570

15. NOZZLE SET

Include in #1:

101603-2430 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-1951 as _

Cross reference number

ZEXEL 101603-2430 1016032430

Zexel num

Bosch num

Firm num

Name

101603-2430

INJECTION-PUMP ASSEMBLY
14BF PE6AD 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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 4.8 4.77 4.83

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 A

Rack position 10

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 114.5 113 116

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.85

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(10)

Boost pressure kPa 18 14 22

Boost pressure mmHg 135 105 165

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 1.5 1.2 1.8

Remarks
Finish

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)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=13 BCL=0.85+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=125.4mm
----------
a=(17deg)+-5deg b=(20deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Start By:a. disassemble governorb. remove fuel injection pumps 1. Remove cover (1) from the fuel injection pump housing. 2. Remove rack (2) from the fuel injection pump housing.
If the original lifters are to be installed in the fuel injection pump housing, put identification marks on them as to their location in the housing.
3. Remove lifters (3) from the fuel injection pump housing. 4. Put the fuel injection pump housing on end on blocks, and use Tool (A) to remove snap ring (4) from the camshaft. 5. Use a soft hammer to push the camshaft toward the governor end of the fuel injection pump housing to loosen washer (5) on the camshaft. Remove washer (5). 6. Remove camshaft (6) from the fuel injection pump housing. 7. Remove bearings (7) from the drive end of the fuel injection pump housing. 8. Remove bearings (8) from the governor end of the fuel injection pump housing.Assemble Fuel Injection Pump Housing
Be sure all oil passages are clear and put clean engine oil on all parts before assembly.1. Use Tool (A) to install bearing (2) in the governor end of the fuel injection pump housing with joint (3) toward the top of the fuel injection pump housing. Install the bearing so it is 0.25 0.20 mm (.010 0.008 in) below the surface of the housing.2. Use Tool (A) to install bearing (1) in the governor end of the fuel injection pump housing so it is 7.16 0.13 mm (0.282 0.005 in) below the surface of the housing. 3. Use Tool (A) to install bearing (4) in the drive end of the fuel injection pump housing with the joint in the bearing toward the top of the fuel injection pump housing. Install the bearing so it is 1.00 0.25 mm (0.039 0.010 in) below the surface of the housing. 4. Install plate assembly (6) of Tool (C) on the drive end of the fuel injection pump housing to install the bearing for the rack. Use clean grease to hold the new rack bearing on driver (5) of Tool (C). Install the driver and bearing in plate assembly (6) with the groove in the driver in alignment with the pin in the plate. Use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against plate assembly (6).5. Remove Tool (C) from the fuel injection pump housing. The rack bearing must be installed so it is 0.25 0.25 mm (0.010 0.010 in) below the surface of the housing. 6. Install camshaft (7) in the fuel injection pump housing.7. Put the fuel injection pump housing on end, and put a block under the camshaft. 8. Put washer (9) over the end of the camshaft, and use Tool (A) and a spacer (8) that has an inside diameter of 38.1 mm (1.5 in) and a length of 31.75 mm (1.25 in) to push the washer