Information injection-pump assembly
ZEXEL
101603-6081
1016036081
Rating:
Service parts 101603-6081 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME035749
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-6081
1016036081
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
131424-5520
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.1
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
88
85.4
90.6
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
275
275
275
Each cylinder's injection qty
mm3/st.
10.5
9
12
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
88
87
89
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
Injection quantity adjustment_04
Adjusting point
C
Rack position
(R1-0.8)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
67
65
69
Fixing the lever
*
Boost pressure
kPa
28
28
28
Boost pressure
mmHg
210
210
210
Injection quantity adjustment_05
Adjusting point
I
Rack position
13.9+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-1.1
Boost pressure
kPa
22
22
22
Boost pressure
mmHg
165
165
165
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
(R1-0.8)
Boost pressure
kPa
28
26.7
29.3
Boost pressure
mmHg
210
200
220
Boost compensator adjustment_03
Pump speed
r/min
700
700
700
Rack position
R1(12.1)
Boost pressure
kPa
48
41.3
54.7
Boost pressure
mmHg
360
310
410
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1300
Advance angle
deg.
1.6
1.1
2.1
Timer adjustment_04
Pump speed
r/min
1400
Advance angle
deg.
3.5
-1.5
8.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B44 BCL=1.1+-0.1mm
----------
----------
T1=B44 BCL=1.1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=33deg+-5deg b=(41deg)+-3deg
----------
----------
a=33deg+-5deg b=(41deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Free (at shipping)
(2)R = corresponding to aa
(3)Set the stopper bolt at speed = rated point and rack position = bb. Confirm non-injection.
(4)After setting the stopper bolt, confirm non-injection at speed = cc and rack position = dd.
----------
aa=17.4mm bb=(7.5)mm cc=275r/min dd=(9)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
----------
aa=17.4mm bb=(7.5)mm cc=275r/min dd=(9)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=400+-5r/min Ra=9.2mm
----------
----------
N1=400+-5r/min Ra=9.2mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Illustration 1 g01955898
Typical exampleThere have been a number of remanufactured 3054C engines that were assembled with a loose 111-3422 Nut (1) for the gear for the injection pump (2). This nut has only received an initial torque of 25 N m (18 lb ft). A second torque of 88 N m (65 lb ft) is required. Without this required torque, the timing of the engine may be affected.The remanufactured part numbers for the engine and serial numbers that have been identified with the loose nut for the fuel injection pump gear are listed in table 1.
Table 1
Part Number of the Engine Arrangement Engine Serial Number
10R-5995 54E09007
54E09008
54E09009
54E09010
54E09011
54E09012
54E09013
54E09063
54E09064
54E09065
54E09066
54E09071
54E09073
54E09074
54E09075
10R-5996 54E09055
54E09056
54E09057
10R-5998 54E09039
54E09058
10R-8791 54E09022
54E09023
54E09024
54E09025
54E09026
54E09028 Solution
The nut that secures the fuel injection pump gear requires a second torque of 88 N m (65 lb ft) prior to engine operation. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure to remove the front cover. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure to tighten the nut.
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Illustration 1 g01955898
Typical exampleThere have been a number of remanufactured 3054C engines that were assembled with a loose 111-3422 Nut (1) for the gear for the injection pump (2). This nut has only received an initial torque of 25 N m (18 lb ft). A second torque of 88 N m (65 lb ft) is required. Without this required torque, the timing of the engine may be affected.The remanufactured part numbers for the engine and serial numbers that have been identified with the loose nut for the fuel injection pump gear are listed in table 1.
Table 1
Part Number of the Engine Arrangement Engine Serial Number
10R-5995 54E09007
54E09008
54E09009
54E09010
54E09011
54E09012
54E09013
54E09063
54E09064
54E09065
54E09066
54E09071
54E09073
54E09074
54E09075
10R-5996 54E09055
54E09056
54E09057
10R-5998 54E09039
54E09058
10R-8791 54E09022
54E09023
54E09024
54E09025
54E09026
54E09028 Solution
The nut that secures the fuel injection pump gear requires a second torque of 88 N m (65 lb ft) prior to engine operation. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure to remove the front cover. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure to tighten the nut.