Information injection-pump assembly
ZEXEL
101693-9100
1016939100
NISSAN-DIESEL
1671395111
1671395111
Rating:
Cross reference number
ZEXEL
101693-9100
1016939100
NISSAN-DIESEL
1671395111
1671395111
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
1-4-2-6-
3-5
Pre-stroke
mm
3.7
3.65
3.75
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
13.6
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
106.4
104.8
108
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
9.9+-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(13.6)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
106.4
105.4
107.4
Basic
*
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
96.7
93.5
99.9
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(12.7)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
62.9
61.9
63.9
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
14.8+-0.
5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
100
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
(12.15)
Boost pressure
kPa
5.3
4
6.6
Boost pressure
mmHg
40
30
50
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R1-1.15
Boost pressure
kPa
9.3
8
10.6
Boost pressure
mmHg
70
60
80
Boost compensator adjustment_03
Pump speed
r/min
550
550
550
Rack position
R1-0.6
Boost pressure
kPa
14.7
14.7
14.7
Boost pressure
mmHg
110
110
110
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)RACK LIMIT
----------
T1=B36
----------
----------
T1=B36
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=26.5deg+-5deg b=43deg+-3deg
----------
----------
a=26.5deg+-5deg b=43deg+-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:
1. Disconnect fuel line (1) from the fuel transfer pump. Disconnect fuel line (2) from the fuel injection pump housing. Remove line (3) from the transducer module and aftercooler housing.2. Disconnect fuel injection lines (4) from the fuel injection pump housing.
Do not disconnect the air line from the air compressor until the air pressure is zero.
3. Loosen the bleed valves, and release the air pressure in the air tank.4. Remove air line (5). Remove coolant line (6). 5. Disconnect wiring harness from bracket (7). Disconnect wires at connectors (8).
Typical Example6. The weight of the fuel injection pump housing and rack actuator package is approximately 57Kg (125 lb.). Attach a hoist to the fuel injection pump housing and remove bolts (9).
Typical Example7. Remove two nuts (on shown) and two bolts (10). Remove bolt (11). Remove the fuel injection pump housing and rack actuator package (12).
Typical Example8. Remove O-ring seals (13) from the fuel injection pump housing.Install Fuel Injection Pump Housing And Rack Actuator Package
1. Attach a hoist to the fuel injection pump housing and rack actuator package (12). Be sure that the three O-ring seals are in position in the fuel injection pump housing. Install the fuel injection pump housing and rack actuator package on the timing gear housing. 2. Connect the wires at connectors (8).
Transducer Module3. Connect P5 to J5 connector, J11 to P11 connector, and P10 to J10 connector. 4. Install air line (5) and coolant line (6).5. Connect fuel injection lines (4) to the fuel injection pump housing. Tighten the fuel injection line nut to a torque of 40 7 N*m (30 5 lb.ft.) with tool (A).6. Connect the fuel line (1) to the fuel transfer pump. Connect fuel line (2) to the fuel injection pump housing. Install line (3) to the transducer module and aftercooler housing. For timing of the fuel injection pump, see Install Timing Advance Unit.End By:a. install timing advance unit
Do not disconnect the air line from the air compressor until the air pressure is zero.
3. Loosen the bleed valves, and release the air pressure in the air tank.4. Remove air line (5). Remove coolant line (6). 5. Disconnect wiring harness from bracket (7). Disconnect wires at connectors (8).
Typical Example6. The weight of the fuel injection pump housing and rack actuator package is approximately 57Kg (125 lb.). Attach a hoist to the fuel injection pump housing and remove bolts (9).
Typical Example7. Remove two nuts (on shown) and two bolts (10). Remove bolt (11). Remove the fuel injection pump housing and rack actuator package (12).
Typical Example8. Remove O-ring seals (13) from the fuel injection pump housing.Install Fuel Injection Pump Housing And Rack Actuator Package
1. Attach a hoist to the fuel injection pump housing and rack actuator package (12). Be sure that the three O-ring seals are in position in the fuel injection pump housing. Install the fuel injection pump housing and rack actuator package on the timing gear housing. 2. Connect the wires at connectors (8).
Transducer Module3. Connect P5 to J5 connector, J11 to P11 connector, and P10 to J10 connector. 4. Install air line (5) and coolant line (6).5. Connect fuel injection lines (4) to the fuel injection pump housing. Tighten the fuel injection line nut to a torque of 40 7 N*m (30 5 lb.ft.) with tool (A).6. Connect the fuel line (1) to the fuel transfer pump. Connect fuel line (2) to the fuel injection pump housing. Install line (3) to the transducer module and aftercooler housing. For timing of the fuel injection pump, see Install Timing Advance Unit.End By:a. install timing advance unit