Information injection-pump assembly
ZEXEL
101608-9610
1016089610
NISSAN-DIESEL
1671395308
1671395308
Rating:
Service parts 101608-9610 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-95019
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101608-9610
as INJECTION-PUMP ASSEMBLY
Include in #2:
104242-3010
as _
Cross reference number
ZEXEL
101608-9610
1016089610
NISSAN-DIESEL
1671395308
1671395308
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
131424-1520
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
1-4-2-6-
3-5
Pre-stroke
mm
3.9
3.85
3.95
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
Adjusting point
-
Rack position
13.8
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
118
116.4
119.6
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9
7.2
10.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.8)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
118
117
119
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
94.5
91.3
97.7
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.55
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
64.5
60.5
68.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
100
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2-0.55
Boost pressure
kPa
10.7
9.4
12
Boost pressure
mmHg
80
70
90
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R2(R1-1.
2)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
920--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
870
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
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
(4)Boost compensator stroke: BCL
----------
T1=J98 BCL=0.55+-0.1mm
----------
----------
T1=J98 BCL=0.55+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
Removal of Lubrication System (1)
Removal of Lubrication System (2)
Disassembly Inspection and Reassembly Of Lubrication System
Oil Pump
Disassembly and Inspection of Oil Pump
Measurement of Clearance between Outer Rotor and Inner Rotor
Measure the clearance between the outer rotor and inner rotor, and, if the limit value is exceeded, replace the pump assembly.
Measurement of clearance between outer rotor and inner rotor Measurement of Rotor and Case End Play
Measure the rotor and case end play, and, if the limit value is exceeded, replace the pump assembly.
Measurement of rotor and case end play Measurement of Clearance Between Outer Rotor and Pump Case
Measure the clearance between the outer rotor and pump case, and, if the limit value is exceeded, replace the pump assembly.
Measure the clearance between the outer rotor and case Reassembly of Oil Pump
Install the outer rotor to the pump case, check alignment mark (indentation) on the pump case cover, and then tighten the bolts. If the alignment marks are not aligned during the reassembly, the pump will not suck oil.
Alignment marks on pump case and pump case coverOil Filter and Oil Cooler
Disassembly and Inspection of Oil Filter and Oil Cooler
Relief Valve
Inspection of Relief Valve
Relief Valve(1) Check the relief valve and valve seat for contact condition, and the spring for fatigue and damage, and replace any defective parts.(2) Measure the valve opening pressure (oil pressure when the engine is running at rated rpm) of the relief valve, and, if the standard valve is exceeded, remove the cap bolt and make an adjustment by increasing or decreasing the shim thickness.Engine oil pressure take-out port Next to oil filter - Rp 1/8 thread (PS 1/8) Installation of Lubrication System (1)
Installation of Lubrication System (2)
Removal of Lubrication System (2)
Disassembly Inspection and Reassembly Of Lubrication System
Oil Pump
Disassembly and Inspection of Oil Pump
Measurement of Clearance between Outer Rotor and Inner Rotor
Measure the clearance between the outer rotor and inner rotor, and, if the limit value is exceeded, replace the pump assembly.
Measurement of clearance between outer rotor and inner rotor Measurement of Rotor and Case End Play
Measure the rotor and case end play, and, if the limit value is exceeded, replace the pump assembly.
Measurement of rotor and case end play Measurement of Clearance Between Outer Rotor and Pump Case
Measure the clearance between the outer rotor and pump case, and, if the limit value is exceeded, replace the pump assembly.
Measure the clearance between the outer rotor and case Reassembly of Oil Pump
Install the outer rotor to the pump case, check alignment mark (indentation) on the pump case cover, and then tighten the bolts. If the alignment marks are not aligned during the reassembly, the pump will not suck oil.
Alignment marks on pump case and pump case coverOil Filter and Oil Cooler
Disassembly and Inspection of Oil Filter and Oil Cooler
Relief Valve
Inspection of Relief Valve
Relief Valve(1) Check the relief valve and valve seat for contact condition, and the spring for fatigue and damage, and replace any defective parts.(2) Measure the valve opening pressure (oil pressure when the engine is running at rated rpm) of the relief valve, and, if the standard valve is exceeded, remove the cap bolt and make an adjustment by increasing or decreasing the shim thickness.Engine oil pressure take-out port Next to oil filter - Rp 1/8 thread (PS 1/8) Installation of Lubrication System (1)
Installation of Lubrication System (2)