101603-9132 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039132

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9132 1016039132

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Service parts 101603-9132 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3290

3. GOVERNOR 105492-0340

4. SUPPLY PUMP 105220-5200

5. AUTOM. ADVANCE MECHANIS 105643-0240

6. COUPLING PLATE 105661-0350

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5440

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3522

14. NOZZLE 105015-7100

15. NOZZLE SET

Include in #1:

101401-4272 as _

101603-9132 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-9132 1016039132

Zexel num

Bosch num

Firm num

Name

101603-9132

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 131424-1520

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)
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 3.3 3.25 3.35

Beginning of injection position
Drive 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 10.5

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 48.3 46.3 50.3

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 9.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 10 8 12

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. 72 72

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3.2 2.7 3.7

Timer adjustment_04

Pump speed r/min 1450

Advance angle deg. 6 5.5 6.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 6.5 6.5 6.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (N = N1) (3)Damper spring setting
----------
SXL=11.4+0.2mm N1=455r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=(18.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=5.5deg+-5deg b=22deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

Measure wear of the cylinder bore at the top and bottom of piston ring travel.(1) Cylinder bore [standard, original size] ... 114.300 to 114.338 mm (4.5000 to 4.5015 in) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 114.452 mm (4.5060 in)Cylinder bore must be made the next size larger when the size of the bore is ... 114.529 mm (4.5090 in)Cylinder bore [0.51 mm (.020 in) larger than the original size] ... 114.821 0.013 mm (4.5205 .0005 in)The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 114.960 mm (4.5260 in)Cylinder bore must be made the next size larger when the size of the bore is ... 115.037 mm (4.5290 in)Cylinder bore [1.02 mm (.040 in) larger than the original size] ... 115.329 0.013 mm (4.5405 .0005 in)Maximum permissible wear of cylinder bores (replacement of the cylinder block is necessary) ... 115.545 mm (4.5490 in)(2) Bore in block for camshaft bearing ... 67.374 0.013 mm (2.6525 .0005 in) Install camshaft bearings with the oil hole toward the top of the cylinder block.(3) Width of main bearing cap ... 166.624 0.018 mm (6.5600 .0007 in) Minimum permissible width of main bearing cap ... 166.573 mm (6.5580 in)Width of main bearing cap guide (in cylinder block) ... 166.599 0.013 mm (6.5590 .0005 in)(4) Bore in block for main bearing ... 94.171 0.013 mm (3.7075 .0005 in) Permissible amount of distortion in bore ... 94.13 to 94.21 mm (3.706 to 3.709 in) (5) Torque for bolts holding caps for main bearings: a. Put 2P2506 Thread Lubricant on bolt threads and washer face.b. Tighten all bolts in number sequence to ... 40 4 N m (30 3 lb ft)c. Put a mark on each bolt and cap.d. Tighten all bolts in number sequence from mark ... 120 5° (6) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 95.250 0.038 mm (3.7500 .0015 in)(7) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 322.66 0.13 mm (12.703 .005 in)
There are holes in the bores for the main bearings, between the cylinders for piston cooling orifices. These holes must have orifices or plugs installed or low oil pressure will be the result.
If the base for the oil cooler is 357.2 mm (14.06 in) long the engine has piston cooling orifices installed. If the base for the oil cooler is 268.2 mm (10.56 in) long the engine has plugs installed.Piston cooling orifices were eliminated from 3208 truck engines effective with truck engine 2Z30692 with a rating of 150 KW (200 hp) @ 2000 rpm or 160 KW (215 hp) @ 2200 rpm. On earlier engines