Information injection-pump assembly
ZEXEL
101401-9250
1014019250
Rating:
Service parts 101401-9250 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
TF33 13 H50
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-9250
1014019250
Zexel num
Bosch num
Firm num
Name
101401-9250
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
12.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
67
66.5
67.5
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.
14.5
12.5
16.5
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(12.5)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
67
66.5
67.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.55
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
81
77
85
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.5
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
47.8
43.8
51.8
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
1000--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
950
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1625
Advance angle
deg.
5
4.5
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=J12
----------
----------
T1=J12
----------
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(12.5)mm Rb=R1-0.4mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=67+-0.5cm3/1000st Q2=(59)+-1cm3/1000st
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(12.5)mm Rb=R1-0.4mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=67+-0.5cm3/1000st Q2=(59)+-1cm3/1000st
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=7deg
----------
a=(130deg)
----------
aa=7deg
----------
a=(130deg)
Information:
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
C175 Injector Sleeve Re-Seal Process:
This Rework Procedure outlines how to correctly remove, inspect, and install a C175 injector sleeve into a cylinder head, with a new process designed to stop coolant leaks caused by injector sleeve seal failure.
Parts and Materials Needed:
8T-2223 Quill Tube Bolts/Cylinder - Qty 4
8T-0106 injector Hold Down Bolt/Cylinder - Qty 1
298-5347 Injector Sleeve/Cylinder - Qty 1
247-1074 Injector Sleeve O-Rings/Cylinder - Qty 2
8C-3132 Injector Tip O-Ring/Cylinder - Qty 1
339-9352 Injector System Cap Kit/Engine - Qty 1
- Battery powered screwdriver/impact
- Soft bristled brush (nylon or other non-metallic material), Cat part number 6V-7096 is an example. Refer to Image1.2.1.
- Injector sleeve torque tool (333-0759, or new tool provided by Lafayette)
- Vacuum attachment, for removing debris from inside cylinder
- Deep well socket, inverted
- Wrap a lint free shop towel around the socket, secure to the socket with an O-ring
- Brake clean or similar solvent
- Torque wrench capable of reaching 200 N.m
- Anti-seize (C5-A Loctite 51007)
- Clean engine oil
Image1.2.1
Removal of Valve Covers:
1. Remove four quill tube bolts and slide quill out of head. Refer to Image1.3.1.
2. Place quill tube into sealed plastic bag.
3. Place plugs into the quill tube hole and over fuel limiter in the fuel rail.
4. Remove the injectors.
5. Place injectors in plastic bag.
Image1.3.1
Removal of the Injector Sleeves:
1. Remove the injector sleeves. Refer to Image 1.4.1.
2. Vacuum out any loose debris.
3. Clean remaining Loctite debris from the injector sleeve seat using brake-clean or a similar solvent, a nylon bristled brush (Cat part number 6V-7096), and an inverted socket with a lint free rag or towel wrapped around it).
4. Use an O-ring to keep the rag around the socket.
5. Clean the threads in the head with the soft bristled brush. Refer to Image1.4.2.
6. Clean the seat surface with the inverted socket and a new rag until the rag no longer picks up debris or dirt from the seat. Refer to Image1.4.3 and 1.4.4.
Image1.4.1
Image1.4.2
Image1.4.3
Image1.4.4
Inspection of the Injector Sleeve Seat:
1. The seat and threads must be free of any debris.
2. The seat must not have any visible guttering around the surface.
3. There should be a continuous shiny band
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101401-9250
INJECTION-PUMP ASSEMBLY