103662-3182 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1036623182

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 103662-3182 1036623182

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Service parts 103662-3182 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103066-8400

3. GOVERNOR 105455-1042

4. SUPPLY PUMP 105235-1781

5. AUTOM. ADVANCE MECHANIS 105649-0010

6. COUPLING PLATE 105664-0200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4133

11. Nozzle and Holder 6162-12-3403

12. Open Pre:MPa(Kqf/cm2) 29.4{300}

13. NOZZLE-HOLDER 105041-7112

14. NOZZLE 105015-6640

15. NOZZLE SET

Include in #1:

101692-1441 as _

103662-3182 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 103662-3182 1036623182

Zexel num

Bosch num

Firm num

Name

103662-3182

INJECTION-PUMP ASSEMBLY
SA6D170A 14BS PE4-8Z PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500

Overflow valve 133424-0420

Overflow valve opening pressure kPa 206 172 240

Overflow valve opening pressure kgf/cm2 2.1 1.75 2.45

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.8 3.75 3.85

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 17.3

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 469 464 474

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 58.7 58.7

Boost pressure mmHg 440 440

Injection quantity adjustment_02

Adjusting point B

Rack position 8.9+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 39 34 44

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 750 750 750

Rack position 13.7

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 18.1

Boost pressure kPa 45.3 45.3 45.3

Boost pressure mmHg 340 340 340

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Minimum - maximum speed specification (2)Target notch: K (3)Stop lever's normal position setting: R1 (4)RACK LIMIT: RAL (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2 (7)Idle sub spring setting: L1.
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K=20 R1=19.2+0.5mm RAL=18.6+0.2mm BCL=4.4+0.1mm N1=1050r/min N2=750r/min L1=8.4-0.5mm
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Speed control lever angle

F:Full speed
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----------
a=(30deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Clearance is bb from where contacts inner stopper. (4)Actual measurement
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aa=80mm bb=(2)mm
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a=(16.5deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb, pump speed cc (3)(Actual measurement) (4)(Actual measurement)
----------
aa=19.2+0.5mm bb=2-0.2mm cc=0r/min
----------

Information:

1. Disconnect fuel lines (1) from fuel transfer pump (3). Remove bolts (2). Remove fuel transfer pump (3). Remove gasket from fuel transfer pump.2. Install a new gasket on fuel transfer pump (3). Install fuel transfer pump on rear plate with the bolts (2) that hold it. Connect fuel lines (1) to the fuel transfer pump.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Make a separation between cover (4) and pump body (2). 3. Remove lip-type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip-type seals and the bottom bearing from pump body (1).8. Remove check valve (13). Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with Tooling (B). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with Tooling (A).3. Install lip-type seal (5) with Tooling (C). Install the seal until it is 24.6 0.5 mm (97 .02) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip-type seal (6) with Tooling (D). Install the seal until it is 14.2 0.5 mm (.56 .02 in) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with Tooling (E). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 316°C (600°F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 0.10 in).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 28 7 N m (22 5 lb ft).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with Tooling (C). Install the seal until it is 3.8 0.5 mm (.15 .02 in) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15), seal plug (13) in pump cover (1). Tighten plug (13) to a torque of 28 4 N m (27 3 lb ft).11. Put 7M-7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body.
Do not let the liquid gasket enter the pump.
The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install tachometer drive on transfer pump cover (1).End By:a. install fuel transfer pump