101693-9390 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016939390

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101693-9390 1016939390

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Cross reference number

ZEXEL 101693-9390 1016939390

Zexel num

Bosch num

Firm num

Name

101693-9390

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 3.9 3.85 3.95

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 12.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 80.8 78.8 82.8

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. 9.6 7.8 11.4

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(12.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 80.8 79.8 81.8

Basic *

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 91.5 88.3 94.7

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 1)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 76.4 73.2 79.6

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.4

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 67 65 69

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 84 84 104

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-0.4

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 1)

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

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 (4)Boost compensator stroke: BCL
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T1=F07 BCL=0.4+-0.1mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
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N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=26.5deg+-5deg b=44deg+-3deg

Stop lever angle

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

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Install the shim (D) to the rod (C) and tighten nut (E). (3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L. (4)Release the rack fixing and mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (-0420) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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L=33-0.2mm N1=700r/min Ra=R1(12.6)mm
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0000001601 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)-
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a=(60deg)

Information:

Start By:a. remove cylinder headb. remove oil panc. remove cooling jets 1. Remove two rod cap bolts (1) from each rod. Remove rod caps (2).2. Using a soft hammer tape rod (3) away from crankshaft and remove bearing half (4). When removing cylinder pack, watch the rod and prevent it from catching on the block bore as it comes out.3. Install tooling (A) and remove cylinder pack (5). 4. Remove cylinder liner seal (6) at the base of the spacer block. 5. Remove the remainder of tooling (A) from cylinder pack (5) and then remove the rod and piston from the cylinder liner. The following steps are for the installation of the cylinder pack.6. Install a new cylinder liner seal, lubricate the seal with engine oil. Some engines use pistons which have the word "FRONT" stamped on the crown of the piston. Make sure the word "FRONT" is toward the front of the engine when the piston is installed. The etched number on the connecting rod must be on the right side and must be installed in the corresponding cylinder. 9U-5839 Liquid Gasket Material is applied to the cylinder liners in the area shown in the illustration. The liquid gasket material helps prevent oil leaks from between the cylinder block and spacer block. DO NOT apply any 9U-5839 Liquid Gasket Material between the engine spacer block and the cylinder block surfaces. Using excessive amounts of liquid gasket material on the liner flange seat can cause oil leaks due to distortion of the O-ring seals between the spacer block and cylinder block.7. Lubricate the lower portion of the cylinder liner with engine oil. Be sure the corresponding crankshaft throw is at bottom center. Position cylinder pack (5) and guide rod (3) into place. Use tooling (B) and press cylinder pack (5) into place.8. With rod (3) in this position, install the upper half of rod bearing (4). Be sure the bearing tab properly engages the slot in the connecting rod. Lubricate the bearing surface with engine oil and tap the piston down with a rubber mallet until the rod and bearing contacts the crankshaft.9. With rod cap bearing in place and oiled, install rod cap (2). Lubricate rod bolts (1) with 2P2506 Thread Lubricant. Install rod bolts (1) and torque to 130 7 N m (95 5 lb.ft.). Mark each bolt head and then tighten each bolt an additional 60 5° (1/6 turn).End By:a. install cooling jets.b. install oil pan.c. install cylinder head.