Information injection-pump assembly
ZEXEL
101601-5210
1016015210
Rating:
Cross reference number
ZEXEL
101601-5210
1016015210
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
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
3.1
3.07
3.13
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
9.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68
67
69
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.1+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68
67
69
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
105
105
115
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
4
3.5
4.5
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=B97
----------
----------
T1=B97
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=33deg+-5deg b=(45deg)+-3deg
----------
----------
a=33deg+-5deg b=(45deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the normal set bolt.
(2)Engine normal
(3)Engine stop
----------
----------
a=(0deg)+-5deg b=(13deg) c=11deg+-5deg d=40deg+-5deg
----------
----------
a=(0deg)+-5deg b=(13deg) c=11deg+-5deg d=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(55deg)
----------
----------
a=(55deg)
Information:
Start By:a. remove oil pumpb. remove oil pan plate
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove No. 1, 3, 5 and 7 main bearing caps (1). Remove the lower halves of the main bearings from the main bearing caps.
If the crankshaft is turned in the wrong direction, the tab on the bearing will be pushed between the crankshaft and the bearing area in the cylinder block. This can result in damage to the cylinder block and/or the crankshaft.
2. Install tool (A) in the hole in the crankshaft journal, and turn the crankshaft to remove the upper halves of main bearings (2).3. Remove crankshaft thrust bearings (3). Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and the main bearing caps.
4. Use tool (A), and install new upper halves of main bearings (2) in the cylinder block. Install new lower halves of main bearings (2) in main bearing caps (1).
When the bearing clearance is checked and the engine is in an upright position (vertical position with cylinder head on top), the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances.
For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.5. Check the main bearing clearance with Plastigage (B) as follows:a. Put a piece of Plastigage (B) on the crankshaft journals as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
b. Put main bearing caps (1) in position in the engine. Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers, and install the bolts. Tighten the bolts to a torque of 40 4 N m (30 3 lb ft).c. Put a mark on each bolt and main bearing cap; then tighten the bolts 90° more.d. Remove the main bearing caps, and measure the Plastigage to find the bearing clearance. The main bearing clearance for new bearings must be 0.076 to 0.165 mm (.0030 to .0065 in). Maximum permissible clearance with used bearings is 0.25 mm (.010 in). 6. Put clean oil on the thrust bearing, and install a new thrust bearing for the rear main bearing. Install the thrust bearing with the identification
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove No. 1, 3, 5 and 7 main bearing caps (1). Remove the lower halves of the main bearings from the main bearing caps.
If the crankshaft is turned in the wrong direction, the tab on the bearing will be pushed between the crankshaft and the bearing area in the cylinder block. This can result in damage to the cylinder block and/or the crankshaft.
2. Install tool (A) in the hole in the crankshaft journal, and turn the crankshaft to remove the upper halves of main bearings (2).3. Remove crankshaft thrust bearings (3). Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and the main bearing caps.
4. Use tool (A), and install new upper halves of main bearings (2) in the cylinder block. Install new lower halves of main bearings (2) in main bearing caps (1).
When the bearing clearance is checked and the engine is in an upright position (vertical position with cylinder head on top), the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances.
For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.5. Check the main bearing clearance with Plastigage (B) as follows:a. Put a piece of Plastigage (B) on the crankshaft journals as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
b. Put main bearing caps (1) in position in the engine. Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers, and install the bolts. Tighten the bolts to a torque of 40 4 N m (30 3 lb ft).c. Put a mark on each bolt and main bearing cap; then tighten the bolts 90° more.d. Remove the main bearing caps, and measure the Plastigage to find the bearing clearance. The main bearing clearance for new bearings must be 0.076 to 0.165 mm (.0030 to .0065 in). Maximum permissible clearance with used bearings is 0.25 mm (.010 in). 6. Put clean oil on the thrust bearing, and install a new thrust bearing for the rear main bearing. Install the thrust bearing with the identification