101695-3610 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016953610

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101695-3610 1016953610

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Cross reference number

ZEXEL 101695-3610 1016953610

Zexel num

Bosch num

Firm num

Name

101695-3610

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

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 8.6

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 28 27 29

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.5+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)RACK LIMIT: RAL (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
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K=20 RAL=15+0.2mm N1=1175r/min N2=650r/min N3=1175r/min N4=400r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=(24deg)+-5deg b=32deg+-3deg c=(27deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=26.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
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a=59deg36min+-3deg b=0deg24min+-30min

Information:

1. Remove the bolts that hold the cylinder head assembly to the cylinder block.
To prevent damage to the two cylinder head-to-cylinder block dowels, keep the cylinder head assembly level during removal and installation.
2. Fasten a hoist to the cylinder head assembly as shown. Carefully remove the cylinder head assembly from the cylinder block. Remove the cylinder head gasket. The weight of the cylinder head assembly can range from 50 to 75 kg (110 to 165 lb). The following steps are for the installation of the cylinder head assembly.3. Be sure the mating surface of the cylinder head assembly and the cylinder block are thoroughly clean.4. Put a new cylinder head gasket in position on the cylinder block. Be sure the head gasket is dry. Fasten a hoist to the cylinder head assembly, and put it in position on the cylinder block.
3114 Cylinder Head Tightening Sequence
3116 Cylinder Head Tightening Sequence Bolts (1) are large diameter bolts (M20). Bolts (2) are small diameter bolts (M10).5. Apply clean engine oil on the threads of the cylinder head assembly mounting bolts.6. Install the bolts that hold the cylinder head assembly to the cylinder block, and tighten them as follows: a. Tighten the large diameter bolts in the number sequence shown to a torque of 150 15 N m (110 11 lb ft).b. Tighten the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).c. Retorque the large diameter bolts in the number sequence shown to a torque of 435 20 N m (320 15 lb ft).d. Tighten the small diameter bolts in the number sequence shown to a torque of 55 7 N m (41 5 lb ft).End By:a. install unit fuel injectorsb. install fuel control linkagec. install rocker arm assemblies and push rodsd. install inlet manifolde. install exhaust manifoldf. install fuel filter and fuel filter base