Information injection-pump assembly
ZEXEL
101603-9120
1016039120
NISSAN-DIESEL
16801Z5500
16801z5500
Rating:
Cross reference number
ZEXEL
101603-9120
1016039120
NISSAN-DIESEL
16801Z5500
16801z5500
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
132424-0620
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
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
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
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Rack position
(11.2)
Vist
V
1.75
1.75
1.75
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
65.7
64.7
66.7
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Injection quantity adjustment_02
Rack position
(8.2)
Vist
V
2.4
2.3
2.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.5
7.7
11.3
Max. variation between cylinders
%
0
-10
10
Test data Ex:
Governor adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
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L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
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N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
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N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
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aa=1mm bb=16mm
----------
a=30deg+-5deg b=29deg+-5deg
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aa=1mm bb=16mm
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a=30deg+-5deg b=29deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
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a=(60deg)
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a=(60deg)
0000001701
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:
(1) 9N5496 Spring for valves (outer): Length under test force ... 45.47 mm (1.790 in)Test force ... 185.0 18.0 N (41.6 4 lb)Use again minimum load at length under test force ... 166 N (37.3 lb)Length of spring at valve open position ... 30.23 mm (1.190 in)Use again minimum load at valve open position ... 600 N (135 lb)Free length after test ... 51.77 mm (2.038 in)Outside diameter ... 39.62 mm (1.560 in)Spring must not be bent more than ... 1.80 mm (.071 in)(1) 9N5495 Spring for valves (inner): Length under test force ... 42.47 mm (1.672 in)Test force ... 91.2 9.0 N (20.5 2 lb)Use again minimum load at length under test force ... 81.9 N (18.4 lb)Length of spring at valve open position ... 27.23 mm (1.072 in)Use again minimum load at valve open position ... 295 N (66.3 lb)Free length after test ... 48.77 mm (1.920 in)Outside diameter ... 26.67 mm (1.050 in)Spring must not be bent more than ... 1.70 mm (.067 in)(2) Distance from the end of the valve to the valve spring spacer seat ... 52.40 0.38 mm (2.063 .015 in)(3) Diameter of valve stem: 7C362 and 9L7682 Intake Valve ... 9.462 0.013 mm (.3725 .0005 in)Use again minimum diameter of the valve stem ... 9.42 mm (.371 in)9L7683 and 9N5125 Exhaust Valve (tapered stem):Head end of valve stem ... 9.411 0.013 mm (.3705 .0005 in)Use again minimum diameter of the head end of valve stem ... 9.37 mm (.369 in)Lock end of valve stem ... 9.436 0.013 mm (.3715 .0005 in)Use again minimum diameter of the lock end of valve stem ... 9.408 mm (.3704 in)Bore in the valve guides (intake and exhaust) ... 9.512 0.013 mm (.3745 .0005 in)Maximum permissible bore in the valve guides (worn): Measure 19.0 mm (.75 in) deep in valve guide bore from both ends of the valve guide ... 9.550 mm (.3760 in)(4) Angle of valve face: Intake valve ... 30° 15'Exhaust valve ... 45° 15'(5) Diameter of valve head (intake valve) ... 53.19 0.13 mm (2.094 .005 in) Diameter of valve head (exhaust valve) ... 45.82 0.13 mm (1.804 .005 in)(6) Thickness of valve lip: Intake valve ... 2.31 mm (.091 in)Use again minimum valve lip thickness ... 1.78 mm (.070 in)Exhaust valve ... 1.60 mm (.063 in)Use again minimum valve lip thickness ... 1.27 mm (.050 in)