101603-9680 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039680

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9680 1016039680

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-9680 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 101603-9680 1016039680

Zexel num

Bosch num

Firm num

Name

101603-9680

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 11.1

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 64.7 63.1 66.3

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 275 275 275

Average injection quantity mm3/st. 10.1 8.3 11.9

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(11.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 64.7 63.7 65.7

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. 86.6 82.6 90.6

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. 59.3 56.1 62.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80 90

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=F17
----------

Speed control lever angle

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

----------
a=26.5deg+-5deg b=39deg+-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:

4. Put clean engine oil on the O-ring seal, and assemble elbow (4) to drain tube (5).5. Put the gaskets in position on the block and on the turbocharger, and install the drain tube assembly. 6. Put a gasket in position between oil supply tube (6) and the turbocharger. Install oil supply tube (6).Disassemble Turbocharger (TV72 & TV78)
START BY:a. remove turbocharger (TV72 & TV78) 1. Install the turbocharger in tool group (A). Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4).
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
3. Install tool (C) in tool (B), and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6). 4. Put the cartridge assembly in tool (E), and use a press (if necessary) to remove compressor wheel (6) from the turbine wheel and shaft assembly. Do not let the turbine wheel and shaft assembly fall during removal of the compressor wheel from the turbine wheel and shaft. 5. Remove seal ring (7) and shroud (8) from turbine wheel and shaft assembly (9). 6. Bend the tabs of the locks from bolts (10), and remove the bolts and locks.7. Remove backplate assembly (11) from the cartridge housing. 8. Remove spacer (12) from backplate assembly (11). Remove seal rings (13) from spacer (12). 9. Remove collar (14), thrust bearing (15) and O-ring seal (16) from the cartridge housing. 10. Remove top bearing (17) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (17).11. Use tool (F), and remove the two rings that hold the top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.12. Use tool (F), and remove the last ring that holds the bottom bearing in position from the cartridge housing.13. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reuseable Parts, Form No. SEBF8018.Assemble Turbocharger (TV72 & TV78)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (1), (4) and (5) must be installed with the round edge of the outside diameter of the rings toward the bearings.
3. Install ring (4) in the cartridge