Information injection-pump assembly
ZEXEL
101441-9660
1014419660
NISSAN-DIESEL
1671290160
1671290160
Rating:
Service parts 101441-9660 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-43G02
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101441-9660
as INJECTION-PUMP ASSEMBLY
Include in #2:
105856-7022
as _
Cross reference number
ZEXEL
101441-9660
1014419660
NISSAN-DIESEL
1671290160
1671290160
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
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
2.3
2.25
2.35
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
A
Rack position
12.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
42.1
41.1
43.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.1+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.9
9.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
900
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
3
3
3
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=13 RAL=14.7-0.3mm N1=750r/min N2=500r/min
----------
----------
K=13 RAL=14.7-0.3mm N1=750r/min N2=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Set the pump speed at aa
(3)Set the pump speed at bb (at delivery)
----------
aa=750r/min bb=900r/min
----------
a=1deg+-5deg b=23deg+-5deg c=6deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=1deg+-5deg b=23deg+-5deg c=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=53deg+-5deg
----------
----------
a=12deg+-5deg b=53deg+-5deg
0000001501 GOV FULL LOAD ADJUSTMENT
Title1:Full load stopper adjustment
Title2:Governor set speed
LABEL1:Distinguishing
LABEL2:Pump speed (r/min)
LABEL3:Ave. injection quantity (mm3/st)
LABEL4:Max. var. bet. cyl.
LABEL5:Remarks
LABEL6:Distinguishing
LABEL7:Governor set speed (r/min)
LABEL8:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)-
----------
----------
a1=A a2=B r1=750r/min r2=750r/min Q1=42.1+-1mm3/st Q2=37.6+-1mm3/st c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min
----------
----------
a1=A a2=B r1=750r/min r2=750r/min Q1=42.1+-1mm3/st Q2=37.6+-1mm3/st c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(100deg)
----------
aa=18deg
----------
a=(100deg)
Information:
Self-Diagnostics
The electronic system has self-diagnostic capabilities. When a problem is detected, a fault indicator is illuminated on the front of the module. A panel of indicators is also located on the MECP.Module Fault Indicators
A fault should be immediately serviced. A fault indicator is illuminated when a problem exists. When the PLC has an active fault, find the appropriate procedure in the troubleshooting section.Operating Information that is Stored in the Programmable Logic Controller
The SLC 5/04 uses a battery in order to provide backup power to the C-MOS RAM.Programmable Logic Controller Chassis or Rack
The PLC chassis contains the following components:
Power Supply
CPU Module
Input Modules
Output Modules
User Defined ModulesThe system uses the Allen-Bradley SLC 500 series of PLC.Central Processing Unit
Illustration 1 g00562937
The SLC 5/04 processor includes a three-position keyswitch on the front panel. The key switches the system from the following three modes of operation: RUN, PROGRAM and REMOTEThe key can be removed in each of the three positions. The mode changes when the position of the key is switched from the RUN position. Do not substitute the keyswitch for a master control relay. Do not substitute the keyswitch for an emergency stop switch.RUN Position
The RUN position places the processor in the run mode. The processor conducts the following functions:
The processor scans the ladder program.
The processor executes the ladder program.
The processor monitors input devices.
The processor energizes the output devices.
The processor acts on the enabled I/O forces.You can only change the processor's mode with the keyswitch. Revising of the program cannot be performed when you are on-line."PROG" Position
The Program position places the processor in the program mode. The processor does not scan the program and the processor does not execute the program. The controller's outputs are de-energized.You can only change the processor's mode with the keyswitch. Revising of the program can be performed when you are on-line.When the keyswitch is in the program position, a qualified technician can use the programmer interface device in order to change the processor's mode.Remote Position
The remote position places the processor in the remote mode. You can only change the processor's mode with the keyswitch. Revising of the program can be performed when you are on-line.When the keyswitch is in the remote position, a qualified technician can use the programmer interface device in order to change the processor's mode.Processor's Fault Indicators
A fault should be immediately serviced. A fault indicator is illuminated when a problem exists. When the PLC has an active fault, find the appropriate procedure in the troubleshooting section.The Processor's Indicators
Six LED indicators are on the front of the CPU module. The indicators show the operating status of your processor. The indicators have the labels that are in the following list:"RUN", "FLT", "BATT", "FORCE", "DH+" and "RS232"Thermocouple Module
The thermocouple module contains diagnostic features that can identify sources of problems. The problems may occur during power up. The problems may occur during normal operation. Each channel can receive a signal from the sensors or from the analog input devices.
Illustration 2 g00562940
LED indicatorsResistance Temperature Detector Module
The RTD module contains diagnostic features that
The electronic system has self-diagnostic capabilities. When a problem is detected, a fault indicator is illuminated on the front of the module. A panel of indicators is also located on the MECP.Module Fault Indicators
A fault should be immediately serviced. A fault indicator is illuminated when a problem exists. When the PLC has an active fault, find the appropriate procedure in the troubleshooting section.Operating Information that is Stored in the Programmable Logic Controller
The SLC 5/04 uses a battery in order to provide backup power to the C-MOS RAM.Programmable Logic Controller Chassis or Rack
The PLC chassis contains the following components:
Power Supply
CPU Module
Input Modules
Output Modules
User Defined ModulesThe system uses the Allen-Bradley SLC 500 series of PLC.Central Processing Unit
Illustration 1 g00562937
The SLC 5/04 processor includes a three-position keyswitch on the front panel. The key switches the system from the following three modes of operation: RUN, PROGRAM and REMOTEThe key can be removed in each of the three positions. The mode changes when the position of the key is switched from the RUN position. Do not substitute the keyswitch for a master control relay. Do not substitute the keyswitch for an emergency stop switch.RUN Position
The RUN position places the processor in the run mode. The processor conducts the following functions:
The processor scans the ladder program.
The processor executes the ladder program.
The processor monitors input devices.
The processor energizes the output devices.
The processor acts on the enabled I/O forces.You can only change the processor's mode with the keyswitch. Revising of the program cannot be performed when you are on-line."PROG" Position
The Program position places the processor in the program mode. The processor does not scan the program and the processor does not execute the program. The controller's outputs are de-energized.You can only change the processor's mode with the keyswitch. Revising of the program can be performed when you are on-line.When the keyswitch is in the program position, a qualified technician can use the programmer interface device in order to change the processor's mode.Remote Position
The remote position places the processor in the remote mode. You can only change the processor's mode with the keyswitch. Revising of the program can be performed when you are on-line.When the keyswitch is in the remote position, a qualified technician can use the programmer interface device in order to change the processor's mode.Processor's Fault Indicators
A fault should be immediately serviced. A fault indicator is illuminated when a problem exists. When the PLC has an active fault, find the appropriate procedure in the troubleshooting section.The Processor's Indicators
Six LED indicators are on the front of the CPU module. The indicators show the operating status of your processor. The indicators have the labels that are in the following list:"RUN", "FLT", "BATT", "FORCE", "DH+" and "RS232"Thermocouple Module
The thermocouple module contains diagnostic features that can identify sources of problems. The problems may occur during power up. The problems may occur during normal operation. Each channel can receive a signal from the sensors or from the analog input devices.
Illustration 2 g00562940
LED indicatorsResistance Temperature Detector Module
The RTD module contains diagnostic features that