101695-3810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016953810

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101695-3810 1016953810

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Cross reference number

ZEXEL 101695-3810 1016953810

Zexel num

Bosch num

Firm num

Name

101695-3810

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 R1(11.9)

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 62 61 63

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_02

Adjusting point -

Rack position 9.7+-0.5

Pump speed r/min 385 385 385

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_03

Adjusting point E

Rack position 15+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 63 53 73

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1

Boost pressure kPa 8.7 6 11.4

Boost pressure mmHg 65 45 85

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.9)

Boost pressure kPa 21.3 14.6 28

Boost pressure mmHg 160 110 210

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)Idle spring not operating. (5)RACK LIMIT: RAL (6)Boost compensator stroke
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K=7 RAL=15+0.2mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=11deg+-5deg b=27deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
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aa=0r/min bb=1-0.2mm
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a=21deg+-5deg b=(55deg)

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) Gear. If new gear is required, replace camshaft assembly. The heat treatment of the gear is damaged if heated.(2) Diameter of the surfaces (journals) for the camshaft bearings (new) ... 69.850 0.013 mm (2.7500 .0005 in) Bore in front bearing for the camshaft (after assembly) ... 69.969 0.048 mm (2.7547 .0019 in)Bore in the other six bearings for the camshaft (after assembly) ... 69.982 0.061 mm (2.7552 .0024 in)(3) Thickness of thrust plate (new) ... 4.65 0.03 mm (.183 .001 in) End play of the camshaft ... 0.10 to 0.26 mm (.004 to .010 in)(4) Camshaft. (5) Height of camshaft lobes.To find lobe height, use the procedure that follows:A. Measure camshaft lobe height (5).B. Measure base circle (7).C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).D. Specified camshaft lobe lift (6) is: Camshaft Assemblya. Exhaust lobe ... 10.5 mm (.413 in)b. Inlet lobe ... 10.5 mm (.413 in)Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is 0.13 mm (.005 in)Inlet Valve Timing
1. Check the No. 1 inlet valve lash with the engine stopped. The valve lash must be 0.30 to 0.46 mm (.012 to .018 in). If the valve lash is not in this range, adjust the lash to 0.38 mm (.015 in).2. Mark Top Center Position of the crankshaft on the vibration damper or pulley.3. Use a dial indicator to measure the inlet valve movement.4. Rotate the crankshaft in the direction of normal engine rotation. Stop when the inlet valve is 1.91 mm (.075 in) off its seat in the opening sequence.At this point the crankshaft Top Center Position Mark must be ... 5 2 degrees After Top CenterChecking Valve-Camshaft Timing (field procedure)
The following procedure will simplify the checking of the camshaft timing procedures.1. Set the No. 3 inlet bridge adjustment. Refer to SENR6547 (Testing And Adjusting).2. Set the No. 3 inlet valve lash. Refer to SENR6547 (Testing And Adjusting).3. Install the bolt in the flywheel with No. 1 piston at top center.4. Install the dial indicator (magnetic base) to No. 3 inlet bridge.5. Remove the bolt from the flywheel.6. Set the indicator at zero and rotate the engine in the normal direction of operation (counterclockwise as viewed from the flywheel end) until dial travel stops.The correct setting should be ... 14.21 0.25 mm (.560 .010 in)