Information injection-pump assembly
ZEXEL
101603-9282
1016039282
Rating:
Service parts 101603-9282 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-9282
1016039282
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 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
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
6-2-4-1-
5-3
Pre-stroke
mm
4.6
4.55
4.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 6-2 deg. 60 59.5 60.5
Cal 6-2 deg. 60 59.5 60.5
Difference between angles 2
Cal 6-4 deg. 120 119.5 120.5
Cal 6-4 deg. 120 119.5 120.5
Difference between angles 3
Cal 6-1 deg. 180 179.5 180.5
Cal 6-1 deg. 180 179.5 180.5
Difference between angles 4
Cal 6-5 deg. 240 239.5 240.5
Cal 6-5 deg. 240 239.5 240.5
Difference between angles 5
Cal 6-3 deg. 300 299.5 300.5
Cal 6-3 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
74.8
73.2
76.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
10.2+-0.
5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
17
15.5
18.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
74.8
73.8
75.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.1
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
80.2
76.2
84.2
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
58.4
54.4
62.4
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
115
130
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Microswitch adjustment unnecessary.
----------
T1=D58
----------
----------
T1=D58
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=65mm
----------
a=24deg+-5deg b=37deg+-3deg
----------
aa=65mm
----------
a=24deg+-5deg b=37deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=35mm
----------
a=25deg+-5deg b=40deg+-5deg
----------
aa=35mm
----------
a=25deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position for the No. 6 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
start by:a) remove turbocharger1. Make a mark on compressor housing (1), cartridge assembly (3) and turbine housing for correct installation. 2. Loosen clamp assemblies (2). Remove compressor housing (1) and cartridge assembly (3) from the turbine housing.3. Put the cartridge assembly in tooling (A).
When nut (5) is loosened, do not put a side force on the shaft.
4. Remove nut (5) and O-ring seal (6). 5. Put the cartridge assembly in a press. Remove the shaft assembly from compressor wheel (7) and cartridge (8). 6. Remove seal ring (10) and shroud (11) from shaft assembly (9).7. Use tooling (B) to remove snap ring (12).
Do not cause damage to insert (13) when it is removed.
8. Install screwdrivers as shown. Carefully lift insert (13) out of the cartridge assembly. 9. Remove sleeve (14) and O-ring seal (15) from the insert. 10. Remove two seal rings (16) from the sleeve.11. Remove deflector (17) from the cartridge assembly. 12. Remove ring (18). 13. Remove sleeve (19) from the cartridge assembly. Make an identification of the position of bearing (20) for assembly purposes.14. Remove bearing (20) from the cartridge assembly. 15. Remove ring (21). 16. Use tooling (C) to remove snap ring (23). Remove sleeve (22) and the lower snap ring. 17. Turn the cartridge housing over. Remove snap ring (26) with tooling (C).18. Remove bearing (25), sleeve (24) and the lower snap ring. Assemble Turbocharger (Schwitzer 4TF555)
Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Put clean engine oil on all parts of the cartridge assembly. 1. Install snap ring (4) with tooling (A) in cartridge housing (1).2. Put sleeve (3) and bearing (2) in position. Install snap ring (5) with tooling (A).3. Turn the cartridge housing over. Install snap ring (8) with tooling (A). 4. Install sleeve (6) and snap ring (7).5. Put ring (10) in position in the cartridge housing. 6. Install bearing (9) with grooved side up. Make an alignment of the dowel in the housing with the hole on the right side of the notch.7. Put sleeve (12) in position. Install ring (11). 8. Put deflector (13) in position as shown. 9. Put two seal rings (15) in position on sleeve (14).10. Put O-ring seal (17) in position on insert (16). 11. Install sleeve (14) in insert (16).12. Install insert assembly (18) with the flange down in the cartridge housing. 13. Put O-ring seal (20) in position.14. Install snap ring (19) with tooling (B). 15. Put shaft assembly (22) in tooling (D). Put 6V2055 High Vacuum Grease in the groove for seal ring (23) at assembly to one half or more of the depth of the groove all the way around the groove. 16. Put seal ring (23) in position on the shaft assembly.17. Install shround (21) on the shaft assembly (22).18. Lightly oil the wheel face that will be under the nut. Put compressor wheel (24) in position.
Do not put a side force on the shaft
When nut (5) is loosened, do not put a side force on the shaft.
4. Remove nut (5) and O-ring seal (6). 5. Put the cartridge assembly in a press. Remove the shaft assembly from compressor wheel (7) and cartridge (8). 6. Remove seal ring (10) and shroud (11) from shaft assembly (9).7. Use tooling (B) to remove snap ring (12).
Do not cause damage to insert (13) when it is removed.
8. Install screwdrivers as shown. Carefully lift insert (13) out of the cartridge assembly. 9. Remove sleeve (14) and O-ring seal (15) from the insert. 10. Remove two seal rings (16) from the sleeve.11. Remove deflector (17) from the cartridge assembly. 12. Remove ring (18). 13. Remove sleeve (19) from the cartridge assembly. Make an identification of the position of bearing (20) for assembly purposes.14. Remove bearing (20) from the cartridge assembly. 15. Remove ring (21). 16. Use tooling (C) to remove snap ring (23). Remove sleeve (22) and the lower snap ring. 17. Turn the cartridge housing over. Remove snap ring (26) with tooling (C).18. Remove bearing (25), sleeve (24) and the lower snap ring. Assemble Turbocharger (Schwitzer 4TF555)
Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Put clean engine oil on all parts of the cartridge assembly. 1. Install snap ring (4) with tooling (A) in cartridge housing (1).2. Put sleeve (3) and bearing (2) in position. Install snap ring (5) with tooling (A).3. Turn the cartridge housing over. Install snap ring (8) with tooling (A). 4. Install sleeve (6) and snap ring (7).5. Put ring (10) in position in the cartridge housing. 6. Install bearing (9) with grooved side up. Make an alignment of the dowel in the housing with the hole on the right side of the notch.7. Put sleeve (12) in position. Install ring (11). 8. Put deflector (13) in position as shown. 9. Put two seal rings (15) in position on sleeve (14).10. Put O-ring seal (17) in position on insert (16). 11. Install sleeve (14) in insert (16).12. Install insert assembly (18) with the flange down in the cartridge housing. 13. Put O-ring seal (20) in position.14. Install snap ring (19) with tooling (B). 15. Put shaft assembly (22) in tooling (D). Put 6V2055 High Vacuum Grease in the groove for seal ring (23) at assembly to one half or more of the depth of the groove all the way around the groove. 16. Put seal ring (23) in position on the shaft assembly.17. Install shround (21) on the shaft assembly (22).18. Lightly oil the wheel face that will be under the nut. Put compressor wheel (24) in position.
Do not put a side force on the shaft