101603-2660 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032660

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2660 1016032660

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Cross reference number

ZEXEL 101603-2660 1016032660

Zexel num

Bosch num

Firm num

Name

101603-2660

INJECTION-PUMP ASSEMBLY

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 9.6

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 109 107 111

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_02

Adjusting point -

Rack position 6.2+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-1.45

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(9.6)

Boost pressure kPa 22.7 16 29.4

Boost pressure mmHg 170 120 220

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)Main spring setting (4)Set idle sub-spring (5)Boost compensator stroke
----------
K=6
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=125.4mm
----------
a=14deg+-5deg b=21deg+-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. remove oil pump 1. Check each connecting rod cap for its location on the crankshaft. Each cap must have a number (1) which is the same as the number on the connecting rod. Do not mix bearings.2. Turn the crankshaft until two of the pistons are at bottom center.3. Remove connecting rod caps (2). Remove the lower bearing from the connecting rod caps.4. Push the connecting rods away from the crankshaft and remove the upper bearings from the connecting rods.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
5. Install the upper bearings in connecting rods. put clean engine oil on the bearings and on the crankshaft journals. Slowly pull the connecting rods on the crankshaft.6. Put clean oil on the lower bearings. Install the lower bearings in the connecting rod caps. Be sure tab (3) on the back of the bearings fits in the groove of the caps and connecting rods. 7. Check the bearing clearance with Plastigage (A) as follows:a. Put clean oil on the threads of bolts (4). Install caps (5), Tool (A) and nuts finger tight.b. Tighten each nut (6) to a torque of 80 8 N m (60 6 lb ft).c. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees more. 8. Remove caps (5) and Plastigage (A). Make sure the connecting rod bearing caps are installed with their identification number in arrangement with the connecting rod number.
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
9. Measure the thickness of the Plastigage to find the bearing clearance. the clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in). The maximum clearance for used bearings is 0.25 mm (0.010 in).10. Install caps (5). Tighten nuts (6) to a torque of 80 8 N m (60 6 lb ft). Tighten the nuts 120 degrees more.11. Do Steps 1 through 10 for the other connecting rod bearings.End By:a. install oil pump