Information injection-pump assembly
ZEXEL
101401-1082
1014011082
Rating:
Service parts 101401-1082 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME017801
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-1082
1014011082
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
131424-6220
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
1-3-4-2
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
55.1
54.1
56.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
10
8.7
11.3
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(10.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
55.1
54.1
56.1
Basic
*
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.6
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
73.5
69.5
77.5
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
39.9
35.9
43.9
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2+0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
35.7
31.7
39.7
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
100
100
100
Average injection quantity
mm3/st.
67
67
72
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-0.4
Boost pressure
kPa
22.7
21.4
24
Boost pressure
mmHg
170
160
180
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R1(10.6)
Boost pressure
kPa
36
29.3
36
Boost pressure
mmHg
270
220
270
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
1700
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B71 BCL=0.4+-0.1mm
----------
----------
T1=B71 BCL=0.4+-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=40mm
----------
a=26deg+-5deg b=42deg+-3deg
----------
aa=40mm
----------
a=26deg+-5deg b=42deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Free (at shipping)
(2)Use the hole at R = aa
(3)Rack position corresponding to bb
(4)Set the stopper bolt so that speed = cc and rack position = dd.
(5)After setting the stopper bolt, confirm non-injection at speed ee. (Rack position = ff or less)
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
0000001501 ACTUATOR
(a) Screw
(B) Nut
Bolt c
(d) Speed lever
(e) Actuator shaft
1. Actuator adjustment procedure
(1)Position the speed lever (d) in the idle position.
(2)Set bolt (c) so that the clearance between the speed lever (d)'s pin and the actuator shaft (e) is approximately L1.
(3)Loosen the nut (b) and fully tighten the screw (a).
(4)Set the pump speed at N1 and read the rack position when negative pressure P1 is applied to the actuator.
(5)Gradually loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1.
(6)Apply negative pressure several times and confirm that the lever (d) returns to the idle position at negative pressure '0.'
(7)Confirm that rack position is R2 when negative pressure is P2.
----------
L1=2mm N1=500r/min P1=66.7kPa(500mmHg) N2=500r/min R1=9.1mm P2=66.7kPa(500mmHg) R2=9.1mm
----------
----------
L1=2mm N1=500r/min P1=66.7kPa(500mmHg) N2=500r/min R1=9.1mm P2=66.7kPa(500mmHg) R2=9.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(130deg)
----------
aa=11deg
----------
a=(130deg)
Information:
Adjusting the engine speeds
To adjust engine speed, remove the cooling fan and install the safety cover over the fan to prevent getting hurt. For speed adjustment specification, see 8-05.(1) The upper limit of engine speed can be adjusted with the HIGH-SPEED stopper bolt.This stopper bolt has been set properly and sealed in the factory before shipping of the engine. Never tamper with the seal unless it is necessary.(2) The lower limit of engine speed can be adjusted with the LOW-SPEED stopper bolt.(3) Never remove the sealing cap unnecessarily to adjust the torque spring set. For the proper disassembling procedure, see 4-02. CAUTION Warm up the engine (until coolant temperature rises up to 60°C or above) before adjusting engine speeds.(4) During running of the engine for speed adjustment, check the engine for gas leak, water leak, oil leak, and fuel leak.(5) After adjustment, perform engine acceleration and deceleration test to confirm that the engine is free from hunting and smoking.
HIGH-SPEED and LOW-SPEED Set BoltsChecking and adjustment of nozzles
To check and adjust the injection nozzles, use the following procedure:1. Injection start pressure(1) Remove the nozzle assembly to be tested from the cylinder head and set the nozzle on the nozzle tester.Perform air bleeding by moving the tester handle up and down.(2) Operate the handle at a speed of 60 rpm or more and read the gauge pressure of fuel injected from the nozzle.* Injection start pressure: 140 +10-0kgf/cm2 [13.7+1.0-0 MPa(3) If reading of gauge pressure is not within the specified range, disassemble the nozzle and vary thickness of the adjusting shim.Increasing or decreasing shim thickness by 0.1 mm will cause injection pressure to vary about 10 kgf/cm2 [0.98 MPa]
Testing Injection Start Pressure(4) When installing the nozzle, use the following values of tightening torque:* Nozzle tightening (to cylinder head) torque: 5.0 - 6.0 kgf m [49 - 59 N m]* Nozzle retaining nut tightening torque: 3.5 - 4.0 kgf m [34 - 39 N m]* Nozzle union collar tightening torque: 2.5 - 3.0 kgf m [25 - 29 N m]
Installing Nozzle Assembly2. Chattering testOperate the tester handle at a speed of about 1 stroke per second.(1) Needle valve oscillationIt is considered normal if the nozzle injects fuel mist, making intermittent sounds, and oscillations of the needle valve are transmitted to the handle.(2) State of fuel mist injectionThe nozzle should inject fuel mist straight in the direction of its axis. A nozzle is defective if it does not inject steadily or it injects fuel in several separate stripes.A nozzle is defective if it spills fuel accumulated on the bottom of the nozzle after chattering test. However, a very small drop of fuel remaining on the tip of nozzle after chattering test may be regarded as normal.
Charttering Test
After-spilling3. Injection testOperate the tester handle at a speed of 4 to 6 strokes per second.* A nozzle should inject fuel mist uniformly in the shape of a cone.4. Checking the compression pressure(1) Make sure of the following:(a) All of the engine oil level, air cleaner,
To adjust engine speed, remove the cooling fan and install the safety cover over the fan to prevent getting hurt. For speed adjustment specification, see 8-05.(1) The upper limit of engine speed can be adjusted with the HIGH-SPEED stopper bolt.This stopper bolt has been set properly and sealed in the factory before shipping of the engine. Never tamper with the seal unless it is necessary.(2) The lower limit of engine speed can be adjusted with the LOW-SPEED stopper bolt.(3) Never remove the sealing cap unnecessarily to adjust the torque spring set. For the proper disassembling procedure, see 4-02. CAUTION Warm up the engine (until coolant temperature rises up to 60°C or above) before adjusting engine speeds.(4) During running of the engine for speed adjustment, check the engine for gas leak, water leak, oil leak, and fuel leak.(5) After adjustment, perform engine acceleration and deceleration test to confirm that the engine is free from hunting and smoking.
HIGH-SPEED and LOW-SPEED Set BoltsChecking and adjustment of nozzles
To check and adjust the injection nozzles, use the following procedure:1. Injection start pressure(1) Remove the nozzle assembly to be tested from the cylinder head and set the nozzle on the nozzle tester.Perform air bleeding by moving the tester handle up and down.(2) Operate the handle at a speed of 60 rpm or more and read the gauge pressure of fuel injected from the nozzle.* Injection start pressure: 140 +10-0kgf/cm2 [13.7+1.0-0 MPa(3) If reading of gauge pressure is not within the specified range, disassemble the nozzle and vary thickness of the adjusting shim.Increasing or decreasing shim thickness by 0.1 mm will cause injection pressure to vary about 10 kgf/cm2 [0.98 MPa]
Testing Injection Start Pressure(4) When installing the nozzle, use the following values of tightening torque:* Nozzle tightening (to cylinder head) torque: 5.0 - 6.0 kgf m [49 - 59 N m]* Nozzle retaining nut tightening torque: 3.5 - 4.0 kgf m [34 - 39 N m]* Nozzle union collar tightening torque: 2.5 - 3.0 kgf m [25 - 29 N m]
Installing Nozzle Assembly2. Chattering testOperate the tester handle at a speed of about 1 stroke per second.(1) Needle valve oscillationIt is considered normal if the nozzle injects fuel mist, making intermittent sounds, and oscillations of the needle valve are transmitted to the handle.(2) State of fuel mist injectionThe nozzle should inject fuel mist straight in the direction of its axis. A nozzle is defective if it does not inject steadily or it injects fuel in several separate stripes.A nozzle is defective if it spills fuel accumulated on the bottom of the nozzle after chattering test. However, a very small drop of fuel remaining on the tip of nozzle after chattering test may be regarded as normal.
Charttering Test
After-spilling3. Injection testOperate the tester handle at a speed of 4 to 6 strokes per second.* A nozzle should inject fuel mist uniformly in the shape of a cone.4. Checking the compression pressure(1) Make sure of the following:(a) All of the engine oil level, air cleaner,