Information injection-pump assembly
ZEXEL
101401-1700
1014011700
Rating:
Cross reference number
ZEXEL
101401-1700
1014011700
Zexel num
Bosch num
Firm num
Name
101401-1700
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
11
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
87.5
86.5
88.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.9+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
70
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
2.5
2
3
Timer adjustment_02
Pump speed
r/min
350
Advance angle
deg.
2.5
2
3
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
500
Advance angle
deg.
0
0
0
Remarks
Finish
Finish
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)Torque spring does not operate.
(4)The torque control spring does not operate.
(5)RACK LIMIT
(6)Set idle sub-spring
(7)Main spring setting
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(12deg)+-5deg b=(28deg)+-5deg
----------
----------
a=(12deg)+-5deg b=(28deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At solenoid operation and speed = aa, rack position must be bb or less (at voltage cc).
----------
aa=0r/min bb=8.4mm cc=24V
----------
a=21.5deg+-5deg b=53deg+-5deg
----------
aa=0r/min bb=8.4mm cc=24V
----------
a=21.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(130deg)
----------
aa=12deg
----------
a=(130deg)
Information:
Crankshaft Grinding Specifications
The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is;.010 in. (0.25 mm) Undersize ... 2.7396 .0006 in.(69.586 0.015 mm).020 in. (0.51 mm) Undersize ... 2.7296 .0006 in.(69.332 0.015 mm).050 in. (1.27 mm) Undersize ... 2.6996 .0006 in.(68.570 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.Width (C) is 2.314 .003 in. (58.77 0.08 mm)Diameter (D) for main bearing journals is:.010 in. (0.25 mm) Undersize ... 3.4895 .0006 in.(88.633 0.015 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0006 in.(88.379 0.015 mm).050 in. (1.27 mm) Undersize ... 3.4495 .0006 in.(87.617 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm)Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 .002 in. (31.95 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3, and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B75621 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 5P3100 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500°F (260°C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Front Oil Seal Removal
Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.
REMOVING FRONT OIL SEAL (Typical Example)Remove Crankshaft Rear Seal And Wear Sleeve
Remove the crankshaft rear oil seal with the 1P3075 Puller Group.
REMOVING REAR OIL SEALInstall a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore.
REMOVING REAR WEAR SLEEVE (Typical Example)Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the
The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is;.010 in. (0.25 mm) Undersize ... 2.7396 .0006 in.(69.586 0.015 mm).020 in. (0.51 mm) Undersize ... 2.7296 .0006 in.(69.332 0.015 mm).050 in. (1.27 mm) Undersize ... 2.6996 .0006 in.(68.570 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.Width (C) is 2.314 .003 in. (58.77 0.08 mm)Diameter (D) for main bearing journals is:.010 in. (0.25 mm) Undersize ... 3.4895 .0006 in.(88.633 0.015 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0006 in.(88.379 0.015 mm).050 in. (1.27 mm) Undersize ... 3.4495 .0006 in.(87.617 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm)Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 .002 in. (31.95 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3, and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B75621 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 5P3100 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500°F (260°C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Front Oil Seal Removal
Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.
REMOVING FRONT OIL SEAL (Typical Example)Remove Crankshaft Rear Seal And Wear Sleeve
Remove the crankshaft rear oil seal with the 1P3075 Puller Group.
REMOVING REAR OIL SEALInstall a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore.
REMOVING REAR WEAR SLEEVE (Typical Example)Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the
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101401-1700
INJECTION-PUMP ASSEMBLY