Information injection-pump assembly
ZEXEL
101605-3310
1016053310
Rating:
Cross reference number
ZEXEL
101605-3310
1016053310
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
13.9
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
82
81
83
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
24
24
Boost pressure
mmHg
180
180
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.6+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
9.6
8.1
11.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
12.5
Boost pressure
kPa
2.7
-1.3
6.7
Boost pressure
mmHg
20
-10
50
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
13.9
Boost pressure
kPa
13.3
9.3
17.3
Boost pressure
mmHg
100
70
130
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Boost compensator stroke
(3)Rack difference between N = N1 and N = N2
----------
K=12 N1=1250r/min N2=400r/min
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K=12 N1=1250r/min N2=400r/min
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Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=17deg+-5deg b=39deg+-5deg c=32deg+-3deg
----------
----------
a=17deg+-5deg b=39deg+-5deg c=32deg+-3deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
Information:
Start By:a. remove flywheel
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal with tool (A). 2. Install tool (C) as shown.3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve in loose.4. Remove tool (C) and the wear sleeve by hand. The following steps are for the installation of the crankshaft rear seal and wear sleeve. 5. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows:a. Put locator (1) in position on the crankshaft and install the three bolts that hold it in place.b. Put clean engine oil on the seal lip of seal (6) and on the outside diameter of wear sleeve (2).c. Install seal (6) on wear sleeve (2) from the end of the wear sleeve that has the bevel on the outside diameter. Make sure the lip of the seal is toward the inside of the engine and the bevel that is on the outside diameter of the wear sleeve is toward the outside of the engine when installed.d. Use 6V1541 Quick Cure Primer to clean the outside diameter of the crankshaft flange (3) and the inside diameter of wear sleeve (2).e. Put 9S3265 Retaining Compound on the outside diameter of crankshaft flange (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.f. Put wear sleeve (2) with seal (6) on locator (1). Put installer (4) on locator (1) and install nut (5). Put lubrication on the face of the washer and the nut.g. Tighten nut (5) until installer (4) comes in contact with locator (1).h. Remove tooling (A) and check the wear sleeve and seal for correct installation.End By:a. install flywheel
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal with tool (A). 2. Install tool (C) as shown.3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve in loose.4. Remove tool (C) and the wear sleeve by hand. The following steps are for the installation of the crankshaft rear seal and wear sleeve. 5. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows:a. Put locator (1) in position on the crankshaft and install the three bolts that hold it in place.b. Put clean engine oil on the seal lip of seal (6) and on the outside diameter of wear sleeve (2).c. Install seal (6) on wear sleeve (2) from the end of the wear sleeve that has the bevel on the outside diameter. Make sure the lip of the seal is toward the inside of the engine and the bevel that is on the outside diameter of the wear sleeve is toward the outside of the engine when installed.d. Use 6V1541 Quick Cure Primer to clean the outside diameter of the crankshaft flange (3) and the inside diameter of wear sleeve (2).e. Put 9S3265 Retaining Compound on the outside diameter of crankshaft flange (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.f. Put wear sleeve (2) with seal (6) on locator (1). Put installer (4) on locator (1) and install nut (5). Put lubrication on the face of the washer and the nut.g. Tighten nut (5) until installer (4) comes in contact with locator (1).h. Remove tooling (A) and check the wear sleeve and seal for correct installation.End By:a. install flywheel