Information injection-pump assembly
ZEXEL
101401-9203
1014019203
Rating:
Service parts 101401-9203 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
TF32 13 H50A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-9203
1014019203
Zexel num
Bosch num
Firm num
Name
101401-9203
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
12.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
66.6
66.1
67.1
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(12.7)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
66.6
66.1
67.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
49.7
45.7
53.7
Fixing the lever
*
Injection quantity adjustment_05
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=H12
----------
----------
T1=H12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
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
----------
0000001601 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(12.7)mm Rb=R1-0.4mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=66.6+-0.5cm3/1000st Q2=-
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(12.7)mm Rb=R1-0.4mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=66.6+-0.5cm3/1000st Q2=-
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 oil pumpb. remove timing gear coverc. remove flywheel housingd. remove pistons For more detail about removal of main bearings, see the topic "Remove & Install Crankshaft Main Bearings" in this module. 1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap.2. Remove bearing caps No. 2 through No. 6. Remove thrust plates from No. 4 upper bearing.3. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 7 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 181 kg (400 lb).
Be careful not to damage the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with Tooling (A).5. Remove dowel and pin from crankshaft with Tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface a distance of 6.4 0.5 mm (.25 .02 in).2. Install dowel (2) until it is extended from the surface a distance of 4.1 0.5 mm (.16 .02 in). 3. Heat crankshaft gear (3) to a maximum temperature of 232°C (450°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft. 5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings, see Remove And Install Crankshaft Main Bearings.6. Check the bearing clearances with Plastigage.7. Put clean engine oil on the bolts for caps No. 1 and No. 7. Install No. 1 and No. 7 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 4 upper main bearing. Install the thrust plates with the side that has identification "BLOCK SIDE" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 6. Install caps No. 2 through No. 6 with the bolts finger tight. Make sure the arrows are toward the front of the block.
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
10. Tighten the cap bolts as follows:a. Tighten the bolts on the tab end of the caps first to a torque of 260 14 N m (190
Be careful not to damage the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with Tooling (A).5. Remove dowel and pin from crankshaft with Tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface a distance of 6.4 0.5 mm (.25 .02 in).2. Install dowel (2) until it is extended from the surface a distance of 4.1 0.5 mm (.16 .02 in). 3. Heat crankshaft gear (3) to a maximum temperature of 232°C (450°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft. 5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings, see Remove And Install Crankshaft Main Bearings.6. Check the bearing clearances with Plastigage.7. Put clean engine oil on the bolts for caps No. 1 and No. 7. Install No. 1 and No. 7 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 4 upper main bearing. Install the thrust plates with the side that has identification "BLOCK SIDE" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 6. Install caps No. 2 through No. 6 with the bolts finger tight. Make sure the arrows are toward the front of the block.
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
10. Tighten the cap bolts as follows:a. Tighten the bolts on the tab end of the caps first to a torque of 260 14 N m (190
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101401-9203
INJECTION-PUMP ASSEMBLY