103662-1790 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1036621790 0429110880


 

Information injection-pump assembly

ZEXEL 103662-1790 1036621790
  0429110880
103662-1790 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 103662-1790 1036621790
  0429110880


Zexel num
Bosch num
Firm num
Name
103662-1790 
103662-2062 
 
0429110880   
INJECTION-PUMP ASSEMBLY
S12N *

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle   105011-9210
Nozzle holder   105043-3000
Opening pressure MPa   34.3
Opening pressure kgf/cm2   350
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2.4-1124
Overflow valve   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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)
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   2.05 2 2.1
Rack position
Point A
  R=A
Beginning of injection position
Governor 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   14
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   400 390 410
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
Remarks
Standard point A's rack position same as row R
 
Injection quantity adjustment_02
Adjusting point   B
Rack position   10
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   240 228 252
Max. variation between cylinders %   0 -5 5
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   7.5+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   68 61.2 74.8
Max. variation between cylinders %   0 -10 10
Fixing the rack   *

Test data Ex:

Governor adjustment

Test data 103662-1790
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle spring not operating. (3)Idle sub spring setting: L1.
----------
K=12 L1=4.5-0.5mm
----------

Speed control lever angle

Test data 103662-1790
F:Full speed S:Stop
----------

----------
a=5.5deg+-5deg b=30deg+-5deg

Stop lever angle

Test data 103662-1790
N:Pump normal S:Stop the pump. I:Idle (1)The clearance must be aa (at normal).
----------
aa=(0.8mm)
----------
a=30deg+-5deg b=21.5deg+-5deg c=12deg+-5deg




Information:

1W4563, 1W5634 Gear Group
(1) Fuel pump drive gear.(2) Washer. Assemble with large diameter away from gear.(3) Bolt. With the timing pin and timing bolt correctly installed, put a clockwise force of 70 N m (50 lb ft) on the drive gear for the fuel pump and tighten bolt to ... 270 25 N m (200 20 lb ft)(4) Fuel pump idler gear. End play for the idler gear (new) ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.86 mm (.034 in)Bore in bearing for the idler gear (new) ... 35.004 0.048 mm (1.3781 .0019 in)Diameter of shaft for idler gear (new) ... 34.902 0.020 mm (1.3741 .0008 in)Clearance between shaft and bearing (new) ... 0.033 to 0.168 mm (.0013 to .0066 in)Maximum permissible clearance between shaft and bearing (worn) ... 0.23 mm (.009 in)(5) Plate. Assemble machined side of plate adjacent to the shaft.(6) Bolt. Tighten to ... 25 7 N m (18 5 lb ft)(7) Camshaft gear.(8) Bolts. Tighten to ... 55 7 N m (40 7 lb ft)(9) Crankshaft gear. Maximum temperature of the gear for installation on the crankshaft ... 316°C (600°F)(10) Idler gear for oil pump.(11) Drive gear for oil pump.2P9642 Gear Group
(1) Fuel pump drive gear.(2) Washer. Assemble with large diameter away from gear.(3) Bolt. With the timing pin and timing bolt correctly installed, put a clockwise force of 70 N m (50 lb ft) on the drive gear for the fuel pump and tighten bolt to ... 149 7 N m (110 5 lb ft)(4) Fuel pump idler gear. End play for the idler gear (new) ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.86 mm (.034 in)Bore in bearing for the idler gear (new) ... 35.004 0.048 mm (1.3781 .0019 in)Diameter of shaft for idler gear (new) ... 34.902 0.020 mm (1.3741 .0008 in)Clearance between shaft and bearing (new) ... 0.033 to 0.168 mm (.0013 to .0066 in)Maximum permissible clearance between shaft and bearing (worn) ... 0.23 mm (.009 in)(5) Plate. Assemble machined side of plate adjacent to the shaft.(6) Bolt. Tighten to ... 25 7 N m (18 5 lb ft)(7) Camshaft gear.(8) Bolts. Tighten to ... 55 7 N m (40 7 lb ft)(9) Crankshaft gear. Maximum temperature of the gear for installation on the crankshaft ... 316°C (600°F)(10) Idler gear for oil pump.(11) Drive gear for oil pump.

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INJECTION-PUMP ASSEMBLY
S12N
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