101609-3390 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093390

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3390 1016093390

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Service parts 101609-3390 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5370

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) 23.5{240}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101609-3390 as INJECTION-PUMP ASSEMBLY

Include in #2:

104265-3040 as _

Cross reference number

ZEXEL 101609-3390 1016093390

Zexel num

Bosch num

Firm num

Name

101609-3390

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 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 100 99 101

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.3+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 11.5 10.5 12.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 115 125

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)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (5)Stop lever at stopping (with the speed lever at full) (6)Set idle sub-spring
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K=8
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
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a=(5deg)+-5deg b=(18deg)+-5deg c=(1deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
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.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min

Information:

(1) Bore in bearing of idler gear ... 28.600 0.048 mm (1.1260 .0019 in) Diameter of shaft for the idler gear ... 28.512 0.013 mm (1.1225 .0005 in)Clearance between bearing and shaft ... 0.028 to 0.150 mm (.0011 to .0059 in)(2) Clearance between gear and body of pump ... 0.05 to 0.66 mm (.002 to .026 in)(3) Diameter of shafts for pump ... 22.217 0.005 mm (.8747 .0002 in) Bore in bearings for shafts ... 22.286 0.051 mm (.8774 .0020 in)Clearance between shafts and bearings ... 0.013 to 0.125 mm (.0005 to .0049 in)(4) Depth that bearings are installed in pump bodies ... 1.52 0.25 mm (.060 .010 in)(5) Gear. Length of gears ... 50.808 0.025 mm (2.0003 .0010 in) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 .0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(6) Length of gears ... 38.070 0.025 mm (1.4988 .0010 in) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 .0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(7) Distance from the end of idler shafts to gear faces ... 21.03 0.13 mm (.828 .005 in) Maximum temperature of gear when shrinking in place ... 398°C (750°F)(8) Distance from the end of the drive shaft to gear face ... 38.23 0.13 mm (1.505 .005 in) Maximum temperature of gear when shrinking in place ... 398°C (750°F)(9) Torque for bolt holding drive gear to drive shaft ... 47 9 N m (35 7 lb ft) Install the bearings in the cover and body for the oil pump so the bearing junctions (joints) are in the position shown (30 15 degrees from centerline).(10) Distance dowel extends from body ... 4.1 0.5 mm (.16 .02 in)(11) Shaft assembly. Distance shaft assembly extends from body ... 30.50 0.25 mm (1.200 .010 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.