101693-9101 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016939101

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101693-9101 1016939101

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Service parts 101693-9101 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3650

3. GOVERNOR 105921-2761

4. SUPPLY PUMP 105220-7060

5. AUTOM. ADVANCE MECHANIS 105614-3311

6. COUPLING PLATE 105661-0601

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6970

11. Nozzle and Holder 16600-95011

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

13. NOZZLE-HOLDER 105031-4620

14. NOZZLE

105015-6600

15. NOZZLE SET

Include in #1:

101607-6410 as _

101693-9101 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101693-9101 1016939101

Zexel num

Bosch num

Firm num

Name

101693-9101

INJECTION-PUMP ASSEMBLY
14BF INJECTION PUMP ASSY 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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.7 3.65 3.75

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 -

Rack position 13.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 106.4 104.8 108

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.9+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.6)

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 106.4 105.4 107.4

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 96.7 93.5 99.9

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_05

Adjusting point C

Rack position R2(12.7)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 62.9 61.9 63.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position 14.8+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 100

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position (12.15)

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R1-1.15

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_03

Pump speed r/min 550 550 550

Rack position R1-0.6

Boost pressure kPa 14.7 14.7 14.7

Boost pressure mmHg 110 110 110

Timer adjustment

Pump speed r/min 920--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 870

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B36
----------

Speed control lever angle

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

----------
a=26.5deg+-5deg b=43deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

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

----------
a=(40deg)

Information:

1. Remove wiring harnesses from bracket (1). 2. Disconnect the wires at connections (5) Remove line (4). Remove five bolts (2), bracket (1) cover (3) and the gasket. 3. Remove two bolts (6) and clamps. Remove rack solenoid. (7) 4. Disconnect wires at connections (8). Remove two bolts (10) and bracket assembly (9). Loosen the locknut and remove rack position sensor (11). Be careful not to lose the spring that is around the sensor. To remove the transducer module at this time use the following procedure.a. disconnect wires at connector (8)b. remove the connector from the wiresc. remove four bolts that fasten transducer module (22) to housing (15)d. feed the wires through housing (18) while removing the transducer module. 5. Remove three bolts (12) from inside housing (14). Remove two bolts (13) and remove housing (14). 6. Loosen locknut (15) and remove engine speed sensor (16). 7. Remove seven bolts (17) and remove the transducer module and housing (18). 8. Remove three bolts (19) and cover (20). 9. Remove two bolts (21). Remove transducer module (22) and gasket. 10. Remove lockring (27), seat (25), spring (24), sleeve (23) and lockring (26). 11. Remove three bolts (28) and remove cylinder (29). 12. Remove sleeve (30), piston (31) and valve (32). Remove O-ring seal (33) from sleeve (30). 13. Remove bolts (34) and remove retainer (35). Remove two races and one bearing (not shown).Assemble Rack Actuator Package
1. Lubricate bearing (37) with engine oil. Install race (36), bearing (37), race (36) and retainer (35) on the fuel injection pump camshaft. 2. Lubricate O-ring seal (33) with engine oil and install on sleeve (30). Install sleeve (32) and piston (31) into sleeve (33). 3. Install sleeve (30) into cylinder (29).4. Install lockring (26), sleeve (23), spring (24), seat (25) and lockring (27) on valve (32). 5. Put cylinder assembly (29) in position on the fuel injection pump housing with piston (31) engaged over fuel injection pump rack (38). Be sure that rack (38) is properly engaged with piston (31). 6. Fasten cylinder (29) to the fuel injection pump housing with three bolts (28). The rack and servo valve (32) must move freely after bolts (28) are tight. 7. Install gasket (39) and transducer module (22) on housing (18). 8. Place wire harness (40) in the slot of the housing. 9. Install cover (20) and bolts (19). 10. Install the gasket and housing (18) on the fuel injection pump housing with seven bolts (17). 11. Install engine speed sensor (16) until it contacts retainer (35). Back the engine speed sensor out (counterclockwise) 180°. This procedure will provide a clearance of .76 mm (.030 in). Tighten locknut (15) to a torque of 13 2 N m (10 1 lb.ft.). 12. Install gasket and housing (14).13. Install the rack position sensor damping seal in housing (14). Install the spring and rack position sensor (11) in housing (14). 14. Connect the rack position sensor wiring connector to the transducer module wiring connector (P8 to