Information injection-pump assembly
ZEXEL
101401-4780
1014014780
NISSAN
1670089TA1
1670089ta1
Rating:
Service parts 101401-4780 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97119-811-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-4780
1014014780
NISSAN
1670089TA1
1670089ta1
Zexel num
Bosch num
Firm num
Name
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
134424-3920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
11.1
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
68.5
66.9
70.1
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
285
285
285
Average injection quantity
mm3/st.
10.5
9.2
11.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.1)
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
68.5
67.5
69.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.55
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
89.5
85.5
93.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.2
Pump speed
r/min
520
520
520
Average injection quantity
mm3/st.
47.6
43.6
51.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.15
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
76
72
80
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1600
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=N20
----------
----------
T1=N20
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=43deg+-5deg b=42deg+-3deg
----------
----------
a=43deg+-5deg b=42deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=960r/min Ra=R1(11.1)mm Vist=2.33+-0.28V
----------
----------
V1=5+-0.01V N1=960r/min Ra=R1(11.1)mm Vist=2.33+-0.28V
----------
0000001601 FICD
(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=400r/min Ra=9.3+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=400r/min Ra=9.3+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Timing device stamping
(4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1.
(5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)
----------
aa=7deg
----------
a=(60deg) b=(85deg)
Information:
Reassembly and adjustment (2-spring nozzle)
Adjust while assembling the parts by the following procedures.As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt before adjustment.The following special tools are necessary for adjustment. Adjusting Steps
(1) Adjustment of nozzle opening pressure(2) Selection of prelift adjusting shims(3) Adjustment of 2-spring adjusting pressure(4) * Check of needle valve full lift(5) Installation of prelift shims(6) * Checking of prelift(7) * Checking of 2-spring adjusting pressure(8) InspectionInspection make operations marked with * as necessary for inspection or confirmation.(1) Adjustment of nozzle valve opening pressure (a) Using the special tool, Retasining Nut for Adjustment, install the nozzle and needle valve to the nozzle holder. 1. Make sure that the knock pin has seated completely in the nozzle before tightening the retaining nut for adjustment. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench.2. Remove the bolt from the tip of the retaining nut. (b) Insert 1st push rod 1st spring, valve opening pressure adjusting shim (first use about 1 mm thick one) and spacer to the nozzle holder. Then tighten the setscrew to specified torque. (c) Install the nozzle holder to the special tool, Nozzle Tester and adjust the shim thickness for nominal injection pressureShim types 0.50, 0.52, 0.54, 0.56, 0.58 0.60, 0.70, 0.80, 0.90, 1.00, 0.10, 0.20, 0.30, 0.40 mm 1. When using a shim, be sure to check its thickness by a micrometer.2. Use same shim for prelift adjustment.3. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa (2.4 kgf/cm2)(2) Selection of prelift adjusting shim(a) 0 point adjustment of Adjusting Device Install the special tool, Dial Gauge to the special tool, Adjusting Device.Install the 2nd push rod to the special tool, Base and install the assembly to a vice.Set the pin and Adjusting Device as indicated in the above illustration and adjust 0 point of the Dial Gauge Use a 60.5 mm long pin.(b) Install the 2nd push rod to the nozzle holder. Do not install the 2nd spring and prelift adjusting shim. (c) Install the Adjusting Device to the setscrew using its intermediate screw.After installation, holding the Dial Gauge at its holder, move it up and down to check that the gauge operates smoothly.Push down the gauge, holding its holder and read its lift h. Read to 1/100 mm(d) Selection of prelift adjusting shim (e) Remove the Adjusting Device from the Nozzle Holder.(3) Adjustment of 2-spring adjusting pressure Install the 2nd spring, adjusting screw and lock nut to the nozzle holder. Do not install the prelift adjusting shim. Using the special tool, Nozzle Tester, adjust the adjusting screw for nominal injection pressure.After adjustment, tighten the lock nut to specified torque.(4) Checking full lift of needle valve (a) Install the special tools indicated in above illustration and set 0 point of the Dial Gauge.(b) Install the nozzle to the Nozzle Tester and operate the tester lever to bleed the inside of
Adjust while assembling the parts by the following procedures.As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt before adjustment.The following special tools are necessary for adjustment. Adjusting Steps
(1) Adjustment of nozzle opening pressure(2) Selection of prelift adjusting shims(3) Adjustment of 2-spring adjusting pressure(4) * Check of needle valve full lift(5) Installation of prelift shims(6) * Checking of prelift(7) * Checking of 2-spring adjusting pressure(8) InspectionInspection make operations marked with * as necessary for inspection or confirmation.(1) Adjustment of nozzle valve opening pressure (a) Using the special tool, Retasining Nut for Adjustment, install the nozzle and needle valve to the nozzle holder. 1. Make sure that the knock pin has seated completely in the nozzle before tightening the retaining nut for adjustment. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench.2. Remove the bolt from the tip of the retaining nut. (b) Insert 1st push rod 1st spring, valve opening pressure adjusting shim (first use about 1 mm thick one) and spacer to the nozzle holder. Then tighten the setscrew to specified torque. (c) Install the nozzle holder to the special tool, Nozzle Tester and adjust the shim thickness for nominal injection pressureShim types 0.50, 0.52, 0.54, 0.56, 0.58 0.60, 0.70, 0.80, 0.90, 1.00, 0.10, 0.20, 0.30, 0.40 mm 1. When using a shim, be sure to check its thickness by a micrometer.2. Use same shim for prelift adjustment.3. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa (2.4 kgf/cm2)(2) Selection of prelift adjusting shim(a) 0 point adjustment of Adjusting Device Install the special tool, Dial Gauge to the special tool, Adjusting Device.Install the 2nd push rod to the special tool, Base and install the assembly to a vice.Set the pin and Adjusting Device as indicated in the above illustration and adjust 0 point of the Dial Gauge Use a 60.5 mm long pin.(b) Install the 2nd push rod to the nozzle holder. Do not install the 2nd spring and prelift adjusting shim. (c) Install the Adjusting Device to the setscrew using its intermediate screw.After installation, holding the Dial Gauge at its holder, move it up and down to check that the gauge operates smoothly.Push down the gauge, holding its holder and read its lift h. Read to 1/100 mm(d) Selection of prelift adjusting shim (e) Remove the Adjusting Device from the Nozzle Holder.(3) Adjustment of 2-spring adjusting pressure Install the 2nd spring, adjusting screw and lock nut to the nozzle holder. Do not install the prelift adjusting shim. Using the special tool, Nozzle Tester, adjust the adjusting screw for nominal injection pressure.After adjustment, tighten the lock nut to specified torque.(4) Checking full lift of needle valve (a) Install the special tools indicated in above illustration and set 0 point of the Dial Gauge.(b) Install the nozzle to the Nozzle Tester and operate the tester lever to bleed the inside of