Information injection-pump assembly
ZEXEL
101693-9370
1016939370
Rating:
Service parts 101693-9370 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5601
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101693-9370
1016939370
Zexel num
Bosch num
Firm num
Name
101693-9370
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
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
12.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
80.8
78.8
82.8
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
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9.6
7.8
11.4
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
80.8
79.8
81.8
Basic
*
Fixing the lever
*
Boost pressure
kPa
21.3
21.3
Boost pressure
mmHg
160
160
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.05
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
91.5
88.3
94.7
Fixing the lever
*
Boost pressure
kPa
21.3
21.3
Boost pressure
mmHg
160
160
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
1)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
76.4
73.2
79.6
Fixing the lever
*
Boost pressure
kPa
21.3
21.3
Boost pressure
mmHg
160
160
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-0.4
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
67
65
69
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
84
84
104
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R2-0.4
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R2(R1-0.
1)
Boost pressure
kPa
8
8
8
Boost pressure
mmHg
60
60
60
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1120
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3
2.5
3.5
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=F07 BCL=0.4+-0.1mm
----------
----------
T1=F07 BCL=0.4+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=26.5deg+-5deg b=44deg+-3deg
----------
----------
a=26.5deg+-5deg b=44deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=40deg+-5deg
----------
----------
a=20deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
1. Disconnect water supply hose from water pump inlet.2. Remove connector pipe (1), remove two bolts (2) and remove oil fill pipe (3). 3. Remove bolts (4) and (5) then remove the water pump. The following steps are for the installation of the water pump.4. Position the water pump and install two bolts (5) and (6). Tighten the two bolts evenly.5. Position connector pipe (1) and gaskets then install the bolts.6. Install oil fill pipe (3). Be sure the gasket is in position between the regulator and pipe and install bolts (2).End By:a. Install alternator (if removed)b. Fill the cooling system to the specified level. See the Maintenance Manual.Disassemble And Assemble Water Pump
Start By:a. remove water pump 1. Remove three bolts (1) and remove cover (2). 2. Use an M12 X 1.75 bolt to force impeller (3) from shaft (4). Install forcing bolt in impeller as indicated by arrow. Hold impeller and screw bolt in until impeller comes off shaft. 3. Remove bolt (5), washer (6), bearing (7) and gear (8). 4. Remove three bolts (9) and remove cover (10) with bearing (11). 5. Press shaft (4) out of seal (12).
Do not allow shaft (4) to fall to the floor, damage may occur to the shaft.
6. Remove seal (12) and seal (13) from water pump housing. The following steps are for the assembly of the water pump. 7. Using driver group, install seal (13). Refer to illustration to see direction of seal lip. Lubricate shaft seal area with engine oil.8. Assemble shaft (4), bearing (11) and cover (10). Position assembly into seal and housing then install bolts (9). 9. Position the housing and shaft assembly in a press. Position seal (12) on shaft (4). 10. Position tool (A) and press seal into place. 11. Position the water pump in a press, position impeller (3) and press it into place. Dimension X is 1.5 0.5 mm (.059 .020 in.).12. Position seal and cover (2), then install bolts (1).End By:a. install water pump
Start By:a. remove water pump 1. Remove three bolts (1) and remove cover (2). 2. Use an M12 X 1.75 bolt to force impeller (3) from shaft (4). Install forcing bolt in impeller as indicated by arrow. Hold impeller and screw bolt in until impeller comes off shaft. 3. Remove bolt (5), washer (6), bearing (7) and gear (8). 4. Remove three bolts (9) and remove cover (10) with bearing (11). 5. Press shaft (4) out of seal (12).
Do not allow shaft (4) to fall to the floor, damage may occur to the shaft.
6. Remove seal (12) and seal (13) from water pump housing. The following steps are for the assembly of the water pump. 7. Using driver group, install seal (13). Refer to illustration to see direction of seal lip. Lubricate shaft seal area with engine oil.8. Assemble shaft (4), bearing (11) and cover (10). Position assembly into seal and housing then install bolts (9). 9. Position the housing and shaft assembly in a press. Position seal (12) on shaft (4). 10. Position tool (A) and press seal into place. 11. Position the water pump in a press, position impeller (3) and press it into place. Dimension X is 1.5 0.5 mm (.059 .020 in.).12. Position seal and cover (2), then install bolts (1).End By:a. install water pump
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101693-9370
INJECTION-PUMP ASSEMBLY