103662-1800 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1036621800 0429110850


 

Information injection-pump assembly

ZEXEL 103662-1800 1036621800
  0429110850
103662-1800 INJECTION-PUMP ASSEMBLY
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Service parts 103662-1800 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP
3. GOVERNOR
4. SUPPLY PUMP 105235-1351
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105663-0150
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2)
13. NOZZLE-HOLDER
14. NOZZLE
15. NOZZLE SET

Include in #1:

103662-1800 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 103662-1800 1036621800
  0429110850


Zexel num
Bosch num
Firm num
Name
103662-1800 
103662-2072 
 
0429110850   
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
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 B
  R=B
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 103664-1030 in row A
 
Injection quantity adjustment_02
Adjusting point   B
Rack position   15
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   470 450 490
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 103662-1800
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1.
----------
K=15 L1=4.5-0.5mm
----------

Speed control lever angle

Test data 103662-1800
F:Full speed S:Stop
----------

----------
a=11deg+-5deg b=30deg+-5deg

Stop lever angle

Test data 103662-1800
N:Pump normal S:Stop the pump. I:Idle
----------

----------
a=30deg+-5deg b=23deg+-5deg c=10deg+-5deg




Information:

(1) 7S7144 Spring for valves (new): Length under test force ... 44.86 mm (1.766 in)Test force ... 257 25 N (57.7 4.5 lb)Use again minimum load at length under test force ... 217 N (48.83 lb)Length of spring at valve open position ... 32.28 mm (1.271 in)Use again minimum load at valve open position ... 658 N (148.5 lb)Free length after test ... 52.07 mm (2.05 in)Outside diameter ... 35.21 mm (1.386 in)Spring must not be bent more than ... 1.82 mm (.072 in)(2) Height to top of valve guide ... 22.23 0.25 mm (.875 .010 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Use again minimum diameter ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head.Minimum permissible (new) ... 9.456 mm (.3723 in)Maximum permissible (worn) ... 9.581 mm (.3772 in)(4) Valve lip thickness: 6N9916 Exhaust Valve Use again minimum ... 2.69 mm (.106 in)7N753 Exhaust Valve Use again minimum ... 2.44 mm (.096 in)2W2620 or 7N752 Intake Valve Use again minimum ... 2.69 mm (.106 in)6N9915 Intake Valve Use again minimum ... 2.44 mm (.096 in)(5) Diameter of valve head: Exhaust valve ... 48.16 0.13 mm (1.896 .005 in)Intake valve ... 51.31 0.13 mm (2.020 .005 in)(6) Angle of valve face ... 29 1/4 1/4° (7) Depth of bore in head for valve seat insert ... 12.28 0.13 mm (.483 .005 in)(8) Diameter of valve seat insert for exhaust valve ... 50.889 0.013 mm (2.0035 .0005 in) Bore in head for valve seat insert for exhaust valve ... 50.813 0.030 mm (2.0005 .0012 in)Diameter of valve seat insert for intake valve ... 52.032 0.013 mm (2.0485 .0005 in)Bore in head for valve seat insert for intake valve ... 51.956 0.030 mm (2.0455 .0012 in)(9) Angle of face of valve seat insert ... 30 1°(10) Maximum permissible width of valve seat (intake and exhaust) ... 1.93 mm (.076 in) Minimum permissible width of valve seat (intake and exhaust) ... 1.14 mm (.045 in)(11) Dimension from top of closed valve to face of head: Minimum permissible dimension for 6N9916 or 7N753 Exhaust Valve ... 0.66 mm (.026 in)Minimum permissible dimension for 6N9915, 2W2620, or 7N752 Intake Valve ... 0.15 mm (.006 in)(12) Outside diameter of the face of the valve seat insert: Exhaust seat ... 46.02 mm (1.812 in)Maximum permissible, exhaust seat ... 47.29 mm (1.862 in)Intake seat ... 49.28 mm (1.940 in)Maximum permissible, intake seat ... 50.55 mm (1.990 in)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°Procedure To Check Intake Valve Timing
1. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the valve clearance is not in this range, adjust the clearance to .038 mm (.015 in).2. Mark Top

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