Information injection-pump assembly
ZEXEL
101693-9380
1016939380
Rating:
Cross reference number
ZEXEL
101693-9380
1016939380
Zexel num
Bosch num
Firm num
Name
101693-9380
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
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
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load
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
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack limit adjustment
(1)Fix the rack at the rack limit position Ra.
(2)Install the shim (D) to the rod (C) and tighten nut (E).
(3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L.
(4)Release the rack fixing and mount the joint (B) and fix.
(5)At this time, confirm that the shim (D) does not interfere with the joint (B).
2. Rack sensor adjustment (-0420)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set the speed to N1 r/min.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F).
(5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR.
(6)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=700r/min Ra=R1(12.6)mm
----------
----------
L=33-0.2mm N1=700r/min Ra=R1(12.6)mm
----------
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. Remove two bolts (1) and remove oil supply line (2). Remove two bolts (3), loosen hose clamp (4) and move drain tube (5) out of the way. 2. Remove four bolts (6) and remove the turbocharger. The following steps are for the installation of the turbocharger.3. Apply 5P3931 Anti-Seize to turbocharger mounting studs. Position turbocharger gasket and turbocharger. Install nuts (6) and tighten to 35 5 N m (26 4 lb.ft.).4. Position drain tube with gasket and install bolts (3), then tighten hose clamp (4). Position oil supply line (2) with gasket and install bolts (1).Disassemble And Assemble Turbocharger
Start By:a. remove turbocharger 1. Place turbocharger in tooling (A). Put alignment marks on all the housings. Loosen clamp (1) and remove housing (2). 2. Loosen clamp (3) and remove cartridge assembly (4). 3. Place cartridge assembly (4) in tooling (B).
Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (5). Do not bend or add stress to the shaft when nut (5) is loosened or tightened.
4. Remove nut (5) and remove compressor wheel (6).5. Remove snap ring (7), then use two screw drivers and remove adapter plate (8). Remove o-ring seal (9) and inspect.6. Remove and inspect bushing and seal (10).7. Remove oil deflector (11) and thrust ring (12).8. Remove bearing (13), sleeve (14) and thrust ring (15).9. Lift housing assembly (19) off of shaft and wheel (20).10. Use snap ring pliers and remove wrap around snap ring (16), then remove double bushing (17).11. Remove seal ring (21) and backplate (18).12. Check all parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instructions Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.13. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been assembled, put clean engine oil into the oil inlet of the turbocharger.14. With shaft and wheel (20) in tooling (B), install seal (21).15. Install double bushing (17) into housing (19) and install wrap around snap ring (16). Position housing assembly (19) onto shaft and wheel (20).16. Install thrust ring (15), bearing (13), sleeve (14) and thrust ring (12). Install oil deflector (11) then bushing and seal (10).17. With oil seal (9) in place, position adapter plate (8) and install snap ring (7).
Do not bend or add stress to the shaft when nut (5) is tightened.
18. Install compressor wheel (6) on the shaft. Put one drop of 9S2365 Retaining Compound on the threads of the shaft. Install nut (5) and torque it to 14.4 0.5 N m (144 5 lb.in.).19. Remove cartridge assembly (4) from tooling (B) and install it into the housing on tooling (A). Align marks and tighten clamp (3).20. Install housing (2). Align marks and
Start By:a. remove turbocharger 1. Place turbocharger in tooling (A). Put alignment marks on all the housings. Loosen clamp (1) and remove housing (2). 2. Loosen clamp (3) and remove cartridge assembly (4). 3. Place cartridge assembly (4) in tooling (B).
Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (5). Do not bend or add stress to the shaft when nut (5) is loosened or tightened.
4. Remove nut (5) and remove compressor wheel (6).5. Remove snap ring (7), then use two screw drivers and remove adapter plate (8). Remove o-ring seal (9) and inspect.6. Remove and inspect bushing and seal (10).7. Remove oil deflector (11) and thrust ring (12).8. Remove bearing (13), sleeve (14) and thrust ring (15).9. Lift housing assembly (19) off of shaft and wheel (20).10. Use snap ring pliers and remove wrap around snap ring (16), then remove double bushing (17).11. Remove seal ring (21) and backplate (18).12. Check all parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instructions Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.13. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been assembled, put clean engine oil into the oil inlet of the turbocharger.14. With shaft and wheel (20) in tooling (B), install seal (21).15. Install double bushing (17) into housing (19) and install wrap around snap ring (16). Position housing assembly (19) onto shaft and wheel (20).16. Install thrust ring (15), bearing (13), sleeve (14) and thrust ring (12). Install oil deflector (11) then bushing and seal (10).17. With oil seal (9) in place, position adapter plate (8) and install snap ring (7).
Do not bend or add stress to the shaft when nut (5) is tightened.
18. Install compressor wheel (6) on the shaft. Put one drop of 9S2365 Retaining Compound on the threads of the shaft. Install nut (5) and torque it to 14.4 0.5 N m (144 5 lb.in.).19. Remove cartridge assembly (4) from tooling (B) and install it into the housing on tooling (A). Align marks and tighten clamp (3).20. Install housing (2). Align marks and
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101693-9380
INJECTION-PUMP ASSEMBLY