101609-3361 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093361

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3361 1016093361

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Service parts 101609-3361 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5311

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101609-3361 as INJECTION-PUMP ASSEMBLY

Include in #2:

104258-5193 as _

Cross reference number

ZEXEL 101609-3361 1016093361

Zexel num

Bosch num

Firm num

Name

101609-3361

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 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 2.5 2.45 2.55

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 9.4

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 92 91 93

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 50.7 50.7

Boost pressure mmHg 380 380

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80 90

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-1.25

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(9.4)

Boost pressure kPa 37.3 37.3 37.3

Boost pressure mmHg 280 280 280

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Boost compensator stroke: BCL (7)When hydraulic cylinder ON: P1
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K=17 BCL=1.25+-0.1mm P1=((392)kPa{(4)kgf/cm2})
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=24deg+-3deg b=29deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
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aa=18deg bb=0deg
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a=54deg54min+-3deg b=9deg+-30min

Information:

(1) Diameter of rocker shaft ... 19.012 to 19.037 mm (.7485 to .7495 in.) Overall length ... 661.1938 mm (26.03125 in.)(2) Inside diameter of rocker arm ... 22.23 to 22.255 mm (.875 go .8762 in.)(3) Outside diameter of bushing ... 22.28 to 22.314 mm (.877 to .8785 in.) Interference fit of bushing in rocker lever ... 0.020 to 0.089 mm (.0008 to .0035 in.)Inside diameter of bushing (after it's reamed) ... 19.063 to 19.101 mm (.7505 to .7520 in.)Clearance of rocker shaft in bushing ... 0.03 to 0.089 mm (.001 to .0035 in.)Maximum permissible clearance ... 0.13 mm (.005 in.) See Rocker Shaft Assembly in TESTING AND ADJUSTING for proper alignment of the oil holes in the bushing and rocker lever.(4) Torque for bolts and nuts that hold rocker shaft assembly to cylinder head (tighten bolts from center outward) ... 75 N m (55 lb.ft.)(5) Install seal in cylinder head before rocker shaft assembly is installed.(6) Overall length of push rod ... 265.58 to 267.72 mm (10.456 to 10.540 in.) Shank diameter ... 7.87 to 7.92 mm (.310 to .312 in.)(7) Tappets (valve lifters): Overall length ... 75.4063 mm (2.96875 in.)Shank outside diameter ... 18.987 to 19.012 mm (.7475 to .7485 in.)Cylinder block tappet bore diameter ... 19.05 to 19.0818 mm (.750 to .75125 in.)Running clearance between tappet and block ... 0.038 to 0.0953 mm (.0015 to .00375 in.)Outside diameter of tappet foot ... 30.163 mm (1.1875 in.) (8) Diameter of camshaft journals: No. 1 journal ... 50.71 to 50.737 mm (1.9965 to 1.9975 in.)Minimum permissible diameter ... 50.660 mm (1.9945 in.)No. 2 journal ... 50.457 to 50.483 mm (1.9865 to 1.9875 in.)Minimum permissible diameter ... 50.406 mm (1.9845 in.)No. 3 journal ... 50.203 to 50.229 mm (1.9765 to 1.9775 in.)Minimum permissible diameter ... 50.152 mm (1.9745 in.)No. 4 journal ... 49.949 to 49.975 mm (1.9665 to 1.9675 in.)Minimum permissible diameter ... 48.898 mm (1.9645 in.)(See topic Cylinder Block for camshaft bore specifications.) (10) Height of the lobes of the camshaft. To get height use the procedure that follows:A. Measure base circle (11).B. Add lobe lift (9) to base circle measurement. Total is camshaft lobe height. Camshaft lobe lift (9) is:Intake ... 7.704 to 7.780 mm (.3033 to .3063 in.)Exhaust ... 7.805 to 7.881 mm (.3073 to .3103 in.)Minimum permissible height of lobes is 0.25 mm (.010 in.) less than measurement in Step B.(12) Torque for camshaft bolt ... 70 N m (50 lb.ft.)(13) End play of camshaft ... 0.10 to 0.41 mm (.004 to .016 in.) Maximum permissible end play ... 0.53 mm (.021 in.)(14) Camshaft thrust washer: Outside diameter ... 72.95 to 73.00 mm (2.872 to 2.874 in.)Cylinder block recess diameter for thrust washer ... 73.03 to 73.28 mm (2.875 to 2.885 in.)Clearance of washer in recess ... 0.03 to 0.33 mm (.001 to .013 in.)Inside diameter ... 44.45 mm (1.750 in.)Thickness ... 5.49 to 5.54 mm (.216 to .218 in.)Cylinder block