Information injection-pump assembly
ZEXEL
101696-9240
1016969240
NISSAN-DIESEL
16713Z6375
16713z6375
Rating:
Service parts 101696-9240 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5578
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101696-9240
1016969240
NISSAN-DIESEL
16713Z6375
16713z6375
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
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
13.2
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
103
101
105
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.
8.6
6.8
10.4
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(13.2)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
103
102
104
Basic
*
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+0.2)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
111.5
108.3
114.7
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1+0.
1)
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
85.5
82.3
88.7
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.3
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
61.5
58.3
64.7
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.
89
89
109
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-1.3
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1+0.
1)
Boost pressure
kPa
13.3
13.3
13.3
Boost pressure
mmHg
100
100
100
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Beginning of advance.
Beginning of advance.
Timer adjustment_02
Pump speed
r/min
450
Advance angle
deg.
1
0.5
1.5
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
(530)
Advance angle
deg.
0
0
0
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1120
Advance angle
deg.
0.5
Timer adjustment_05
Pump speed
r/min
1400
Advance angle
deg.
4
3.5
4.5
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=J60 BCL=1.3+-0.1mm
----------
----------
T1=J60 BCL=1.3+-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=36mm
----------
a=20.5deg+-5deg b=39deg+-3deg
----------
aa=36mm
----------
a=20.5deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=28mm
----------
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+-0.02 V, then tighten the nut (F).
(5)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(13.2)mm
----------
----------
L=33-0.2mm N1=700r/min Ra=R1(13.2)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:
This is a 5.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Make sure you have read and understood all of this document before beginning work.
Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on or around the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.
1 - Remove the SCR (selective catalyst reduction) side heat shields in order to gain access to the SCR cover. Remove all of the bolts, plates & SCR cover panel. Clean the old gasket material from the Clean Emission Module (CEM) & SCR cover panels.
Reference Image 1.2.1
Image1.2.1
2 - With a new gasket (351-9235) install the SCR cover panel (351-6791), backing plates (351-6794 & 351-6795), washers (7X7729) and original M10 bolts (8T4182) onto the CEM in the following locations:
(7) top center holes
(7) bottom center holes
(1) LH middle hole
(1) RH middle hole
Hand tighten these bolts.
On each corner install a 1" thick plate (512-8186) with (2) washers (7X7729) and (2) longer M10 bolts (8T5005).
Hand tighten these bolts.
Install a nut (5P7970 onto