Information injection-pump assembly
ZEXEL
101401-9173
1014019173
Rating:
Service parts 101401-9173 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
TF01 13 H50
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-9173
1014019173
Zexel num
Bosch num
Firm num
Name
101401-9173
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
131424-3420
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
3.3
3.25
3.35
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
-
Rack position
12.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
64.6
64.1
65.1
Max. variation between cylinders
%
0
-2.5
2.5
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
325
325
325
Average injection quantity
mm3/st.
9
7
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
64.6
64.1
65.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.45
Pump speed
r/min
1625
1625
1625
Average injection quantity
mm3/st.
79.3
75.3
83.3
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
47.4
43.4
51.4
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
160
160
Fixing the lever
*
Timer adjustment
Pump speed
r/min
700
Advance angle
deg.
0.3
Timer adjustment_02
Pump speed
r/min
1625
Advance angle
deg.
3.8
3.5
4.1
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=E03
----------
----------
T1=E03
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=36mm
----------
a=20deg+-5deg b=(41deg)+-3deg
----------
aa=36mm
----------
a=20deg+-5deg b=(41deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(29.5deg)+-5deg
----------
aa=39mm
----------
a=14deg+-5deg b=(29.5deg)+-5deg
0000001501 LEVER
CL:Center line of camshaft
ST:Stop adjuster screw
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
1. Stop lever adjustment outline
(1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position.
(2)Set the speed lever in the full speed position.
(3)At pump speed Na, position the rack at non-injection position Ra.
(4)Set the stop adjusting screw to fix the speed lever in the idling position.
(5)Confirm that there is no injection at pump speed Nb.
----------
Na=1825r/min Nb=325r/min Ra=4.7+-0.3mm
----------
----------
Na=1825r/min Nb=325r/min Ra=4.7+-0.3mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(140deg)
----------
aa=11deg
----------
a=(140deg)
Information:
Start By:a. remove vibration damper and pulley 1. Use a punch or Tool (A) to put a hole in seal (1). Use Tool (A) to remove seal (1) from the timing gear cover. When a replacement of the front seal is made, a replacement of the wear sleeve is to be made also. 2. Put Tool (B) in position in the seal bore as shown.3. Install Tool (C) between Tool (B) and the wear sleeve. Turn Tool (C) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.4. Remove Tool (B) and the wear sleeve by hand.Install Crankshaft Front Seal & Wear Sleeve
The wear sleeve and seal must be installed at the same time.1. Install the crankshaft front seal and wear sleeve with Tool (A) as follows: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V-1541 Quick Cure Primer. Make an application of 9S-3265 Retaining Compound to crankshaft outside diameter and wear sleeve inside diameter before the wear sleeve is installed on the crankshaft.b. Install locator (1) and the bolts on the front of the crankshaft.c. The wear sleeve and seal come as a set with the seal already installed on the wear sleeve. Make sure the lip of the seal is toward the inside of the engine as shown and the outside diameter bevel of the wear sleeve is toward the outside of the engine.d. Put the wear sleeve and seal in position on locator (1). e. Put installer (2) in position on locator (1).f. Put clean engine oil on the face of nut (3) and its contact area on installer (2). Install nut (3) on stud of locator (1).g. Tighten nut (3) until the inside surface of installer (2) comes in contact with locator (1).h. Remove Tool (A) and check the wear sleeve and seal for correct installation.End By:a. install vibration damper and pulley
The wear sleeve and seal must be installed at the same time.1. Install the crankshaft front seal and wear sleeve with Tool (A) as follows: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V-1541 Quick Cure Primer. Make an application of 9S-3265 Retaining Compound to crankshaft outside diameter and wear sleeve inside diameter before the wear sleeve is installed on the crankshaft.b. Install locator (1) and the bolts on the front of the crankshaft.c. The wear sleeve and seal come as a set with the seal already installed on the wear sleeve. Make sure the lip of the seal is toward the inside of the engine as shown and the outside diameter bevel of the wear sleeve is toward the outside of the engine.d. Put the wear sleeve and seal in position on locator (1). e. Put installer (2) in position on locator (1).f. Put clean engine oil on the face of nut (3) and its contact area on installer (2). Install nut (3) on stud of locator (1).g. Tighten nut (3) until the inside surface of installer (2) comes in contact with locator (1).h. Remove Tool (A) and check the wear sleeve and seal for correct installation.End By:a. install vibration damper and pulley
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101401-9173
INJECTION-PUMP ASSEMBLY