Information injection-pump assembly
ZEXEL
101605-3710
1016053710
Rating:
Cross reference number
ZEXEL
101605-3710
1016053710
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
1-5-3-6-
2-4
Pre-stroke
mm
4
3.95
4.05
Beginning of injection position
Drive side NO.1
Drive 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
A
Rack position
10.2
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
80.9
79.9
81.9
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
40
40
Boost pressure
mmHg
300
300
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
12.3
11.1
13.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
11.3
Boost pressure
kPa
13.3
9.3
17.3
Boost pressure
mmHg
100
70
130
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
11.8
Boost pressure
kPa
26.7
26.7
26.7
Boost pressure
mmHg
200
200
200
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Boost compensator stroke
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=17 N1=1100r/min N2=750r/min N3=1100r/min N4=500r/min
----------
----------
K=17 N1=1100r/min N2=750r/min N3=1100r/min N4=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(10deg)+-5deg b=(21deg)+-5deg
----------
----------
a=(10deg)+-5deg b=(21deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
(2)Stopper bolt setting
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
Information:
1. Remove oil supply tube (1) and suction bell and tube (2). 2. Remove bolts (3) that hold the oil pump to the cylinder block, and remove oil pump (4). The following steps are for installation of the oil pump.3. Put oil pump (4) in position on the cylinder block. Install the bolts that hold the oil pump to the cylinder block.4. Put clean engine oil on the O-ring seals of the tubes.5. Install oil supply tube (1) and suction bell and tube (2).End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A), and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B), and remove the bearings from the cover. 7. Remove gears (5) and (6) from pump body (4).8. Use tooling (B), and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 ° 15 ° from the center line of the oil pump outlet passage (7). 2. Install idler gear (5) and drive gear (6) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (B), and install the bearings in cover (2). Install the bearings so the joint in the bearings is 30 ° 15 ° from the center line of the bearing bores toward oil pump outlet passage (7).4. Install bypass valve (8), spring (9) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump
Start By:a. remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A), and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B), and remove the bearings from the cover. 7. Remove gears (5) and (6) from pump body (4).8. Use tooling (B), and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 ° 15 ° from the center line of the oil pump outlet passage (7). 2. Install idler gear (5) and drive gear (6) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (B), and install the bearings in cover (2). Install the bearings so the joint in the bearings is 30 ° 15 ° from the center line of the bearing bores toward oil pump outlet passage (7).4. Install bypass valve (8), spring (9) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump