103662-1810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1036621810 0429110820


 

Information injection-pump assembly

ZEXEL 103662-1810 1036621810
  0429110820
103662-1810 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 103662-1810 1036621810
  0429110820


Zexel num
Bosch num
Firm num
Name
103662-1810 
103662-2082 
 
0429110820   
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 103662-1810
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 103662-1810
F:Full speed S:Stop
----------

----------
a=11.5deg+-5deg b=30deg+-5deg

Stop lever angle

Test data 103662-1810
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:

C. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.D. Tighten the compressor wheel retainer nut to ... 30 3 N m (264 24 lb in)
Do not bend or add stress to the shaft when nut is tightened.
(7) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 to .8767 in) Outside diameter of the bearing (new) ... 22.144 to 22.154 mm (.8718 to .8722 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)(8) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(9) Put 5P3931 Anti-Seize Compound on threads and tighten bolts that hold turbocharger to manifold to ... 55 5 N m (40 4 lb ft)Schwitzer S4D
(1) End play for shaft (new) ... 0.114 0.038 mm (.0045 .0015 in) Maximum permissible end play (worn) ... 0.20 mm (.008 in)(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 0.03 mm (.211 .001 in)(3) Bore in housing (new) ... 24.994 to 25.006 mm (.9840 to .9845 in) Outside diameter of the bearing (new) ... 24.882 to 24.892 mm (.9796 to .9800 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)(5) Install the compressor wheel (at room temperature) as follows: a. Put the compressor wheel in position on the shaft.b. Put a small amount of clean engine oil on the shaft threads.c. Install the nut on the shaft, and tighten the nut to a torque of 14 to 17 N m (125 to 150 lb in).
Do not bend or add stress to the shaft when nut is loosened or tightened.
d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3265 Retaining Compound.e. Install the nut on the shaft, and tighten the nut to a torque of 4 N m (30 lb in).f. Tighten nut more as follows: For 99.0 mm (3.90 in) diameter compressor wheels, tighten the nut an additional 90°.For 86.4 mm (3.40 in) diameter compressor wheels, tighten the nut an additional 60°.(6) Tighten both band clamps with procedure that follows: a. Tighten to ... 14 1.1 N m (125 10 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 14 1.1 N m (125 10 lb in)
Do not overtighten the clamps.
(7) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(8) Diameter of shaft (new) ... 15.997 to 16.005 mm (.6298 to .6301 in) Bore in the bearing (new) ... 16.035 to 16.043 mm (.6313 to .6316 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold the

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