101603-9730 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016039730

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-9730 1016039730

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Cross reference number

ZEXEL 101603-9730 1016039730

Zexel num

Bosch num

Firm num

Name

101603-9730

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
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T1=F17
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Bottom lever
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aa=39mm
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a=26.5deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=20deg+-5deg b=40deg+-5deg

0000001501 LEVER

(a) Speed lever (B) Accelerator lever (C) Accelerator lever stopper bolt (D) Full speed side (E) idle side 1. Accelerator lever setting method With speed lever at idle position, from point S contact Back off the accelerator lever stopper bolt L and set. (Turn bolt L turns and set.)
----------

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r=36mm L=1+0.5mm

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:

2. Remove bolts (1) from the adapter. Loosen turbocharger compressor housing clamp (2), and rotate turbocharger tube (3) out of the way of the aftercooler housing. 3. Put identification marks on the bolts which hold the aftercooler cover in position for installation purposes. Remove bolts (4) that hold the aftercooler cover to the aftercooler housing. Remove aftercooler cover (5). 4. Remove four bolts (6), elbow (7), the two adapters and pipe (8). 5. Remove four bolts (9), elbow (10) and two adapters (11). 6. Remove aftercooler core (12) from aftercooler housing (13). 7. Remove O-ring seals (14) and gaskets (15) if necessary.Install Aftercooler Core
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. Lubricate all O-ring seals with clean engine oil at assembly. 2. Install O-ring seals (1). Fasten gaskets (2) to both sides of the aftercooler core flange with 5H2471 Cement. 3. Put aftercooler core (3) in position in the aftercooler housing with the end that has the identification "Jacket Water, Fresh Air" toward the water inlet end of the aftercooler housing. 4. Install cover (4) on the aftercooler housing. Be sure to install the long bolts in the thru bolt holes.
To prevent damage to the aftercooler core, tighten the bolts that hold the aftercooler core before tightening the bolts that hold the adapters.
5. Tighten the aftercooler core cover bolts to a torque of 25 7 N m (18 5 lb.ft.). Tighten the bolts again after engine is operated to a torque of 25 7 N m (18 5 lb.ft.). 6. Install gasket (5) and adapter (6) on the aftercooler housing. 7. Install adapter (7) on adapter (6). 8. Put O-ring seals (8) on pipe (9), and install pipe (9) into elbow (10). 9. Install elbow (11) on pipe (9). Put gasket (12) in position between elbow (11) and adapter (7), and fasten the elbow to aftercooler housing with four bolts. 10. Install gasket (13) and adapter (14) on the aftercooler housing. 11. Install adapter (15) on adapter (14). 12. Put O-ring seal (16) in position on tube (17), and install elbow (18) on tube (17). Put gasket (19) in position between elbow (18) and adapter (15), and fasten the elbow to the aftercooler housing with four bolts. 13. Rotate turbocharger tube (20) into position. Place a gasket between the aftercooler housing and adapter, and install the four bolts and nuts that hold it.14. Tighten turbocharger clamp nut (21) to a torque of 18 3 N m (13 2 lb.ft.). Lightly hit all around the clamp with a soft faced hammer, and tighten the clamp nut again to the same torque value.15. Fill the engine with coolant to the correct level. See the Maintenance Guide.