101603-9420 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039420

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9420 1016039420

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Service parts 101603-9420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3330

3. GOVERNOR 105921-3680

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105614-3290

6. COUPLING PLATE 105661-0401

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6690

11. Nozzle and Holder 16600-Z5519

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

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE

105015-6380

15. NOZZLE SET

Include in #1:

101603-9420 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5590 as _

Cross reference number

ZEXEL 101603-9420 1016039420

Zexel num

Bosch num

Firm num

Name

101603-9420

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 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 3.4 3.35 3.45

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 11.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 66.3 64.7 67.9

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 H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 7.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 66.3 65.3 67.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73 69.8 76.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.8)

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 81 77 85

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 84 84 94

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

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=B55
----------

Speed control lever angle

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

----------
a=26.5deg+-5deg b=(34deg)+-3deg

Stop lever angle

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

----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

(1) Maximum permissible temperature of the gear for installation on the camshaft (do not use a torch) ... 315°C (600°F)(2) Tight fit between the gear and camshaft ... 0.037 to 0.123 mm (.0015 to .0048 in)(3) Diameter of the surfaces (journals) for the camshaft bearings (new) ... 69.850 0.013 mm (2.7500 .0005 in) Bore in front bearing for the camshaft (after assembly) ... 69.969 0.048 mm (2.7547 .0019 in)Bore in the other six bearings for the camshaft (after assembly) ... 69.982 0.061 mm (2.7552 .0024 in)(4) Thickness of thrust plate (new) ... 4.65 0.03 mm (.183 .001 in) End play of the camshaft ... 0.10 to 0.26 mm (.004 to .010 in) (5) Height of camshaft lobes.To find lobe height, use the procedure that follows:A. Measure camshaft lobe height (5).B. Measure base circle (7).C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).D. Specified camshaft lobe lift (6) is:4W2430 Camshaft Assembly
a. Exhaust lobe ... 10.211 mm (.4020 in)b. Intake lobe ... 10.211 mm (.4020 in)7W3797 Camshaft Assembly
a. Exhaust lobe ... 10.210 mm (.4020 in)b. Intake lobe ... 10.212 mm (.4021 in)Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is 0.13 mm (.005 in).Intake Valve Timing
1. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the valve clearance is not in this range, adjust the clearance to 0.38 mm (.015 in).2. Mark Top Center Position of the crankshaft on the vibration damper or pulley.3. Use a dial indicator to measure the intake valve movement.4. Rotate the crankshaft in the direction of normal engine rotation. Stop when the intake valve is 1.91 mm (.075 in) off its seat in the opening sequence.At this point the crankshaft Top Center Position Mark must be in position as follows: Engines with the 4W2430 Camshaft Assembly ... 7 2° After Top CenterEngines with the 7W3797 Camshaft Assembly ... 1 2° After Top CenterChecking Valve-Camshaft Timing (field procedure)
The following factory procedure as described in the December 11, 1989 Service Magazine article will simplify in the field checking of the camshaft timing procedures.1. Set the No. 3 intake bridge adjustment.2. Set the No. 3 intake valve clearance.3. Install the bolt in the flywheel with No. 1 piston at top center.4. Install the dial indicator (magnetic base) to No. 3 intake bridge.5. Remove the bolt from the flywheel.6. Set the gauge at zero and rotate the engine in the normal direction of operation (counterclockwise as seen from the flywheel end) until dial travel stops.The following chart indicates the correct setting.