Information injection-pump assembly
ZEXEL
101402-9630
1014029630
YANMAR
12391051010
12391051010
Rating:
Service parts 101402-9630 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-9630
1014029630
YANMAR
12391051010
12391051010
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
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
4.2
4.15
4.25
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
10.7
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
85
84
86
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.6+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
16
15
17
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
120
110
130
Fixing the lever
*
Rack limit
*
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)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
----------
K=11
----------
----------
K=11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=9deg+-5deg b=24deg+-5deg
----------
----------
a=9deg+-5deg b=24deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At delivery
----------
----------
a=58deg+-5deg b=53deg+-5deg
----------
----------
a=58deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Start By:a. remove engine
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Unplug the connector and remove speed pickup (1) to prevent damage to the unit.2. Install tool (A) on the flywheel as shown and fasten a hoist.3. Remove bolts (2) and flywheel (3). The weight of the flywheel is 72 kg (160 lb.).4. If necessary, remove the ring gear from the flywheel with a hammer and punch. The following steps are for the installation of the flywheel.
The ring gear must be installed with the chamfered side of the teeth up as shown in the inset of illustration A89844P2. This will put the chamfered side of the gear teeth toward the starter when the flywheel is installed so the starter will engage correctly.
1. Heat ring gear (4) to a maximum temperature of 320° C (608° F). Install the ring gear. 2. Install tooling (A) on the flywheel in the same position it was during removal. Install two 5/8" - 18 NF guide bolts in the crankshaft if necessary.3. Make an alignment of timing mark (5) on the crankshaft and timing mark (6) on the flywheel. Hold flywheel (3) in position and install bolts (2). Tighten bolts (2) to a torque of 205 27 N m (151 20 lb ft).4. Remove tool (A).5. Install speed pickup (1). Hand tighten speed pickup (1) until it makes contact with the flywheel. Loosen speed pickup (1) one half turn (180°) after contacting the flywheel. Tighten the locknut on speed pickup (1) and the connect wiring harness.End By:a. install engine
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Unplug the connector and remove speed pickup (1) to prevent damage to the unit.2. Install tool (A) on the flywheel as shown and fasten a hoist.3. Remove bolts (2) and flywheel (3). The weight of the flywheel is 72 kg (160 lb.).4. If necessary, remove the ring gear from the flywheel with a hammer and punch. The following steps are for the installation of the flywheel.
The ring gear must be installed with the chamfered side of the teeth up as shown in the inset of illustration A89844P2. This will put the chamfered side of the gear teeth toward the starter when the flywheel is installed so the starter will engage correctly.
1. Heat ring gear (4) to a maximum temperature of 320° C (608° F). Install the ring gear. 2. Install tooling (A) on the flywheel in the same position it was during removal. Install two 5/8" - 18 NF guide bolts in the crankshaft if necessary.3. Make an alignment of timing mark (5) on the crankshaft and timing mark (6) on the flywheel. Hold flywheel (3) in position and install bolts (2). Tighten bolts (2) to a torque of 205 27 N m (151 20 lb ft).4. Remove tool (A).5. Install speed pickup (1). Hand tighten speed pickup (1) until it makes contact with the flywheel. Loosen speed pickup (1) one half turn (180°) after contacting the flywheel. Tighten the locknut on speed pickup (1) and the connect wiring harness.End By:a. install engine