101605-0050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016050050

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101605-0050 1016050050

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Cross reference number

ZEXEL 101605-0050 1016050050

Zexel num

Bosch num

Firm num

Name

101605-0050

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

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 9.3

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 71 69.5 72.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 105 100 110

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
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K=18
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Speed control lever angle

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

----------
a=13deg+-5deg b=24deg+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(100deg)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove bolts (1) and rocker shaft assembly (2). Remove the O-ring seal from the rear rocker arm support bracket.2. Put identification marks on push rods (3) as to their location in the engine. Remove the push rods. The following steps are for the installation of the rocker shaft assembly and push rods.3. Loosen the adjusting screws (4). This will prevent a bent valve or push rod during installation of the rocker shaft assembly. Install push rods (3). The O-ring seal in the rear support must be installed new each time the bolt is removed from the rear support bracket.4. Install rocker shaft assembly (2).
Make sure the dowels on each end of the rocker shaft assembly are in alignment with the holes in the cylinder head.
5. Put 2P2506 Thread Lubricant on all of bolts (1) except for bolt (10) that goes through the rear rocker arm support bracket. Install the bolts in the rocker shaft assembly.6. Tighten bolts (1) for the rocker shaft as follows: a. Tighten all the bolts in number sequence to a torque of 155 N m (115 lb ft).b. Tighten all the bolts again in number sequence to a torque of 250 17 N m (185 13 lb ft).c. Last, tighten bolts again in number sequence (hand tighten only to a torque of 250 17 N m (185 13 lb ft).7. The assembled length of springs at both ends of rocker shaft must be 1.50 0.25 mm (.059 .010 in). Remove or install washers behind springs to change the assembled length of the springs.8. Make adjustments until the intake valve clearance is .038 mm (.015 in) and the exhaust valve clearance is 0.64 mm (.025 in). See the topic, Valve Clearance Setting, in Testing And Adjusting. Tighten the locknuts (2) for the adjusting screws (1) to a torque of 29 7 N m (21 5 lb ft).End By:a. install valve cover.Disassemble And Assemble Rocker Shaft
Start By:a. remove rocker shaft and push rods
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove O-ring seal (1). A replacement of the O-ring seal must be made each time the head bolt is removed from the rear support bracket. 2. Remove retainer ring (6), washer (5), spring (4) washer (3) and rocker arm (2). 3. Remove pin from rear support bracket with a hammer and punch. Remove rear support bracket (7).4. Remove remainder of rocker arms, springs, washers and brackets.5. Remove plugs from each end of the shaft if necessary. The following steps are for the assembly of the rocker shaft. 6. Install rocker arms (2), brackets (8), washers (5) and springs (4) on the rocker shaft.7. Install rear support bracket (7). Make sure the hole in rear support bracket is in alignment with the hole in rocker shaft.8. Install pin (9)