101603-9340 ZEXEL Calibration Data 1016039340

Information Cross number Calibration Data Calibration Data Ex

Information

ZEXEL 101603-9340 1016039340

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Service parts 101603-9340 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4640

3. GOVERNOR 105410-9860

4. SUPPLY PUMP 105210-4151

5. AUTOM. ADVANCE MECHANIS 105614-4400

6. COUPLING PLATE 105662-0590

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6021

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-5010

14. NOZZLE

105015-5390

15. NOZZLE SET

Include in #1:

101603-9340 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-1060 as _

Cross reference number

ZEXEL 101603-9340 1016039340

Zexel num

Bosch num

Firm num

Name

101603-9340

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 131424-5120

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 1-5-3-6- 2-4

Pre-stroke mm 4.5 4.45 4.55

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 A

Rack position 9.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 107.5 105.5 109.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 17.2 15.2 19.2

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 125 165

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100++

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 4.5 4.5 4.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
----------
K=11 N1=1100r/min N2=700r/min N3=1100r/min N4=400r/min
----------

Speed control lever angle

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

----------
a=6deg+-5deg b=25deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=2.5deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(7deg)

Information:

1. Remove carbon seal dam (2) with pliers. Remove compression seal (1). 2. Install a new compression seal on the nozzle. Install a new carbon seal dam with tool (B).3. Make sure the bore in the cylinder head and the fuel inlet fittings are clean.4. Install new O-ring seals on adapter (3) and fuel injection nozzle (4).5. Install the fuel injection nozzle in the head. Turn and push the nozzle into its correct position. Never put lubricant on the nozzle or bore in the cylinder head. 6. Install the adapter in the head. Connect the nozzle and fuel injection line to the adapter. Tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.).7. Install the spacer and clamp (5) that hold the nozzle to the cylinder head. end by:a) install rocker shaftsDisassemble Fuel Injection Nozzles (9N3979 & 1W5829)
start by:a) remove fuel injection nozzles Do not disassemble any nozzle until test has shown it is needed. Check each nozzle with tool (A) for leakage, the pressure, at which the nozzle opens, and the shape and amount of fuel (spray pattern) that comes out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that cannot be corrected with an adjustment or cleaning and can cause engine damage. See TESTING 9N3979 & 1W5829 FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
Keep the work area and all tools extra clean. Be careful not to cause damage to the parts while the nozzles are disassembled and assembled.
1. Remove cap (1) from the fuel injection nozzle.2. Put the nozzle in tool (B). Put tool (B) and the nozzle in a vise. Do not put any part of a nozzle directly in a vise. Loosen locknut (2) while the lift adjustment screw is held. Turn the lift adjustment screw (3) counterclockwise one turn. Hold the lift adjustment screw (3) with a 5/64" hex wrench and remove the locknut (2).
If the lift adjustment screw is not turned counterclockwise one turn, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.
3. Loosen the locknut (4) that holds the pressure adjustment screw. Use tool (D) to hold the pressure adjustment screw. 4. While the nozzle is held in one hand, tilt the nozzle and remove the pressure adjusting screw and locknut, spring, seat and valve. 5. If the valve does not slide out of the nozzle, install tool (C) and remove valve as follows: a) Push valve into nozzle with tool (C) until valve is against bottom of nozzle.b) Push down on body of tool (C) to engage collet on valve with tool (C). c) Turn nut counterclockwise and remove valve from the nozzle body. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must