101603-9620 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039620

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9620 1016039620

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Cross reference number

ZEXEL 101603-9620 1016039620

Zexel num

Bosch num

Firm num

Name

101603-9620

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 134424-1520

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 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 11.4

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 63 61.4 64.6

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. 9.2 7.4 11

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(11.4)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 63 62 64

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.65

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 84.5 80.5 88.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 58 54.8 61.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 82 82 92

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1220--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1170

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1470

Advance angle deg. 5 4.7 5.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=E88
----------

Speed control lever angle

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

----------
a=26.5deg+-5deg b=40deg+-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:

Bearings
Anti-Friction Bearings
When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash the bearings in nonflammable cleaning solution and allow them to drain dry. The bearings may be dried with compressed air, but DO NOT SPIN THE BEARING. Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. DO NOT unwrap new bearings until time of installation.The life of an anti-friction bearing will be shortened if not properly lubricated.Double Row, Tapered Roller
Double row, tapered roller bearings are precision fit during manufacture and the components are not interchangeable. The cups, cones and spacers are usually etched with the same serial number and letter designator. If no letter designators are found, wire the components together to assure correct installation. Reusable bearing components should be installed in their original positions.Heating Bearings
Bearings which require expansion for installation should be heated in oil not to exceed 121°C (250°F). When more than one part is heated to aid in assembly, they must be allowed to cool and then pressed together again. Parts often separate as they cool and shrink.Installation
Lubricate new or used bearings before installation. Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate preloading. When installing a bearing, spacer or washer against a shoulder on a shaft, be sure the chamfered side is toward the shoulder. When pressing bearings into a retainer or bore, apply pressure to the outer race. If the bearing is pressed on the shaft, apply pressure on the inner race.Preload
Preload is an initial force placed on the bearing at the time of assembly.Determine preload or end clearance form the Specifications Section of this Service Manual. Care should be exercised in applying preload. Misapplication of preload to bearings requiring end clearance can result in bearing failure.Sleeve Bearings
DO NOT INSTALL SLEEVE BEARINGS WITH A HAMMER. Use a press, if possible and apply the pressure directly in line with the bore. If it is necessary to drive on a bearing, use a driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part.