101607-1062 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016071062


 

Information injection-pump assembly

ZEXEL 101607-1062 1016071062
101607-1062 INJECTION-PUMP ASSEMBLY
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Service parts 101607-1062 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8280
3. GOVERNOR 105931-7500
4. SUPPLY PUMP 105210-4661
5. AUTOM. ADVANCE MECHANIS 105643-0670
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7140
11. Nozzle and Holder ME076615
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}
13. NOZZLE-HOLDER 105030-4290
14. NOZZLE 105015-8480
15. NOZZLE SET

Include in #1:

101607-1062 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101607-1062 1016071062


Zexel num
Bosch num
Firm num
Name
101607-1062 
 
   
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   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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.2 3.15 3.25
Beginning of injection position
Governor 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   -
Rack position   11.6
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   72.5 70.3 74.7
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   8.3 7.1 9.5
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.6)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   72.5 71.5 73.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.15
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   79.5 75.5 83.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.65
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   71.5 67.5 75.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.8+-0. 2
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   120 100 140
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.9 0.4 1.4
Timer adjustment_03
Pump speed r/min   1380
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-1062
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL
----------
T1=F14 RAL=14.8+-0.2mm
----------

Speed control lever angle

Test data 101607-1062
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=20deg+-5deg b=(40deg)+-3deg

Stop lever angle

Test data 101607-1062
N:Pump normal S:Stop the pump. (1)Pump speed = aa and rack position = bb (non-injection rack position) (2)Set the stopper bolt (confirm non-injection).
----------
aa=1400r/min bb=6.9-0.5mm
----------
a=11.5deg+-5deg b=25deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

0000001601 LEVER

Test data 101607-1062
(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(40deg)+-3deg c=20deg+-5deg

Timing setting

Test data 101607-1062
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(1deg)




Information:

The problems in this section are problems that do come about and are normally called "low power". These problems are not necessarily more common than engine problems, but they are possible problems which you need to read and check before an engine is disassembled.Read all of the items but make sure the first three are checked completely before making any engine test. Possible Causes/Corrections Tachometer ErrorTo check, connect a tachometer of known accuracy to the engine. Run the engine and make a comparison of the readings of the vehicle and test tachometers. If vehicle tachometer is defective, make repairs as necessary or install a new tachometer. Engine Operated At High AltitudeLess oxygen at higher altitudes causes the engine horsepower to go down. There is no effect on the horsepower of the engine for the first 2280 m (7500 ft) above sea level of operation. Brakes Do Not Completely ReleaseCheck the brakes by feeling all the brake drums. If the brakes of a wheel do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck lifted with a jack, the wheels must have free rotation when turned by hand. Extra Engine Driven EquipmentAir compressors, hydraulic pumps, alternator, and other engine driven equipment that has damage, or that was not installed correctly, or that is not in correct adjustment, can take more horsepower to drive than expected. If necessary, disconnect the equipment and test the engine. Speedometer ErrorA defective speedometer does not give the correct speed or the correct indication of fuel consumption. An indication of low speed can cause the operator to feel that he has a power problem. Speeds Too HighThe need for more horsepower is easy to see as the speed of the vehicle is increased. This is especially true if the front of the vehicle has a large surface area. Application personnel can give you the horsepower necessary for different vehicle designs at different speeds. Overload On VehicleApplication personnel can give you the horsepower needs for different vehicles. High Moving ResistanceSoft ground conditions cause a need for more horsepower. To see if the problem is the engine, test the vehicle on a surface known to be good, or test on a chassis dynamometer. High Wind ResistanceThe horsepower needs for a truck can be divided into two parts. Part of the horsepower is used to move the vehicle and part is used to get through the resistance of the wind. The horsepower necessary to get through the resistance of the wind will increase as the vehicle is used at higher speeds. Vehicles with a large front area have a higher wind resistance and take more horsepower than those with a small front area. Some types of trucks, for example those used for the transportation of automobiles and or boats have high wind resistance even if the front area is small. Moving against the wind has the same effect on wind resistance as does higher

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