Information injection-pump assembly
ZEXEL
101607-1001
1016071001
Rating:
Service parts 101607-1001 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076615
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101607-1001
1016071001
Zexel num
Bosch num
Firm num
Name
101607-1001
INJECTION-PUMP ASSEMBLY
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
3.15
3.25
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
11.6
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
72.5
70.3
74.7
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.
8.3
7.1
9.5
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.6)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
72.5
71.5
73.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
79.5
75.5
83.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.65
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
71.5
67.5
75.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
14.8+-0.
2
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
120
100
140
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.9
0.4
1.4
Timer adjustment_03
Pump speed
r/min
1380
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT: RAL
----------
T1=F14 RAL=14.8+-0.2mm
----------
----------
T1=F14 RAL=14.8+-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(40deg)+-3deg
----------
aa=35mm
----------
a=33deg+-5deg b=(40deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
----------
aa=50mm bb=1400r/min cc=6.9-0.5mm
----------
a=25deg+-5deg b=25deg+-5deg
----------
aa=50mm bb=1400r/min cc=6.9-0.5mm
----------
a=25deg+-5deg b=25deg+-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=400r/min Ra=9.2+-0.1mm
----------
----------
N1=400r/min Ra=9.2+-0.1mm
----------
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=11deg
----------
a=(1deg)
----------
aa=11deg
----------
a=(1deg)
Information:
(1) Thickness of spacer plate ... 9.970 0.025 mm (.3925 .0010 in) Thickness of spacer plate gasket ... 0.208 0.025 mm (.0082 .0010 in) For height of liner over top of spacer plate make reference to Cylinder Liner Projection.(2) Camshaft bearing bore (installed) ... 58.80 0.06 mm (2.315 .002 in) Bore in block for camshaft bearings ... 65.100 0.025 mm (2.5630 .0010 in)(3) Bore in block for main bearings (standard size) ... 96.926 0.013 mm (3.8160 .0005 in) Bore in block for main bearings 0.51 mm (.020 in) oversize ... 97.436 0.013 mm (3.8361 .0005 in)(4) Dimension from center of main bearing bore to top of cylinder block (new) ... 383.515 0.165 mm (15.0990 .0064 in)(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 153.99 0.10 mm (6.063 .004 in)(6) Tighten bolts holding bearing caps for main bearings to a torque of: a. Put 6V4876 Molycoat Lubricant on threads and washer face.b. Tighten all bolts to a torque of ... 41 4 N m (30 3 lb ft)c. Put a mark on each bolt and cap.d. Tighten all bolts from mark ... 90 5 degrees Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block.(7) Clearance between main bearing cap and cylinder block ... 0.033 mm (.0013 in) tight to ... 0.043 mm (.0017 in) loose Main bearing cap width ... 165.095 0.020 mm (6.4998 .0008 in)Width of cylinder block for main bearing cap ... 165.100 0.018 mm (6.5000 .0007 in) (8) Piston cooling orifice.
There are holes in the bores for the main bearings, between the cylinders for piston cooling orifices. These holes must have orifices (8) installed.
(9) Distance two dowels extend from the surface of the cylinder block ... 19.8 0.5 mm (.78 .02 in)(10) Distance hollow dowel extends from the surface of the cylinder block ... 16.0 0.5 mm (.63 .02 in)(11) Depth to install two dowels below the surface of the cylinder block (apply 7M7456 Bearing Mount) ... 1.0 0.5 mm (.04 .02 in)(12) Distance dowels extend from the front face of the cylinder block ... 22.4 0.5 mm (.88 .02 in)(13) Distance stud extends from the front face of the cylinder block ... 15.7 0.5 mm (.62 .02 in)(14) Distance two dowels extend from the rear face of the cylinder block ... 12.7 0.5 mm (.50 .02 in) Check piston cooling jets by passing a .090 mm (.0035 in) diameter drill rod thru jet and a .050 mm (.0020 in) circle located at J. Dimensions
There are holes in the bores for the main bearings, between the cylinders for piston cooling orifices. These holes must have orifices (8) installed.
(9) Distance two dowels extend from the surface of the cylinder block ... 19.8 0.5 mm (.78 .02 in)(10) Distance hollow dowel extends from the surface of the cylinder block ... 16.0 0.5 mm (.63 .02 in)(11) Depth to install two dowels below the surface of the cylinder block (apply 7M7456 Bearing Mount) ... 1.0 0.5 mm (.04 .02 in)(12) Distance dowels extend from the front face of the cylinder block ... 22.4 0.5 mm (.88 .02 in)(13) Distance stud extends from the front face of the cylinder block ... 15.7 0.5 mm (.62 .02 in)(14) Distance two dowels extend from the rear face of the cylinder block ... 12.7 0.5 mm (.50 .02 in) Check piston cooling jets by passing a .090 mm (.0035 in) diameter drill rod thru jet and a .050 mm (.0020 in) circle located at J. Dimensions
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101607-1001
INJECTION-PUMP ASSEMBLY