Information injection-pump assembly
ZEXEL
101441-9720
1014419720
NISSAN-DIESEL
1671290163
1671290163
Rating:
Service parts 101441-9720 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
Cross reference number
ZEXEL
101441-9720
1014419720
NISSAN-DIESEL
1671290163
1671290163
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
2.15
2.1
2.2
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
11.3
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
47
46
48
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.3+-0.5
Pump speed
r/min
400
400
400
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
(500)
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1800
Advance angle
deg.
4.7
4.2
5.2
Remarks
Finish
Finish
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=9 RAL=14+-0.1mm N1=1500r/min N2=550r/min
----------
----------
K=9 RAL=14+-0.1mm N1=1500r/min N2=550r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Set the pump speed at bb.
(3)Stopper bolt setting
----------
aa=1800r/min bb=1500r/min
----------
a=32deg+-5deg b=20deg+-5deg c=8deg+-5deg
----------
aa=1800r/min bb=1500r/min
----------
a=32deg+-5deg b=20deg+-5deg c=8deg+-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=- r1=1500r/min r2=- Q1=47mm3/st Q2=- c1=+-2.5% c2=- a3=36 a4=30 r3=1800r/min r4=1500r/min
----------
----------
a1=A a2=- r1=1500r/min r2=- Q1=47mm3/st Q2=- c1=+-2.5% c2=- a3=36 a4=30 r3=1800r/min r4=1500r/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=16deg
----------
a=(100deg)
----------
aa=16deg
----------
a=(100deg)
Information:
Test Procedure
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.The thermocouple module has five LED indicators. Four of the LED indicators are "Channel Status" indicators. The "Channel Status" indicators are numbered according to the channel. One of the LED indicators is a "Module Status" indicator.Diagnostics are displayed on the "Module Status" LED indicator. Operating errors are displayed on the "Module Status" LED indicator. Problems may be detected during powerup or problems may be detected during operation. When an error occurs, the module will not communicate with the processor. The channel is disabled and the data is cleared.
Illustration 1 g00563417
Diagram of the LED indicators
Illustration 2 g00563392
Diagram of the LED indicators
Illustration 3 g00563575
Diagram of the RTD module
Illustration 4 g00563579
Schematic of the RTD moduleFunctional Test
The "Module Status" LED is on. The module is operating normally. Stop.
The "Channel Status" LED is on. The module is operating normally. Stop.
The "Module Status" LED is off. The module is in a fault condition. Proceed to 6.
The "Channel Status" LED is off. The channel is not enabled. This is normal if the sensor is not wired.
The "Channel Status" LED is blinking. The module is in a fault condition. Proceed to 10.
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 7.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Check the LED indicator on the module.
Connect the power supply.
Cycle the power to the module.The results of the preceding procedure are in the following list:
No errors are displayed on the LED indicators. Stop.
Errors are displayed on the LED indicators. Proceed to 8.
Check the module for a fault.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
To avoid potential damage to the processor, handle all modules by the ends of the carrier or edges of the plastic housing. Skin oil or dirt can corrode metallic surfaces, inhibiting electrical contact.
Disconnect the power supply.
Remove the module from the chassis.Reference: Maintenance Procedure, "Input Module
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.The thermocouple module has five LED indicators. Four of the LED indicators are "Channel Status" indicators. The "Channel Status" indicators are numbered according to the channel. One of the LED indicators is a "Module Status" indicator.Diagnostics are displayed on the "Module Status" LED indicator. Operating errors are displayed on the "Module Status" LED indicator. Problems may be detected during powerup or problems may be detected during operation. When an error occurs, the module will not communicate with the processor. The channel is disabled and the data is cleared.
Illustration 1 g00563417
Diagram of the LED indicators
Illustration 2 g00563392
Diagram of the LED indicators
Illustration 3 g00563575
Diagram of the RTD module
Illustration 4 g00563579
Schematic of the RTD moduleFunctional Test
The "Module Status" LED is on. The module is operating normally. Stop.
The "Channel Status" LED is on. The module is operating normally. Stop.
The "Module Status" LED is off. The module is in a fault condition. Proceed to 6.
The "Channel Status" LED is off. The channel is not enabled. This is normal if the sensor is not wired.
The "Channel Status" LED is blinking. The module is in a fault condition. Proceed to 10.
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 7.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Check the LED indicator on the module.
Connect the power supply.
Cycle the power to the module.The results of the preceding procedure are in the following list:
No errors are displayed on the LED indicators. Stop.
Errors are displayed on the LED indicators. Proceed to 8.
Check the module for a fault.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
To avoid potential damage to the processor, handle all modules by the ends of the carrier or edges of the plastic housing. Skin oil or dirt can corrode metallic surfaces, inhibiting electrical contact.
Disconnect the power supply.
Remove the module from the chassis.Reference: Maintenance Procedure, "Input Module