Information
ZEXEL
106871-9101
1068719101
Rating:
Service parts 106871-9101 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/24.5{250}
15.
NOZZLE SET
Include in #1:
106871-9101
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-9101
1068719101
Zexel num
Bosch num
Firm num
Name
106871-9101
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-0820
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
1-8-6-2-
7-5-4-3
Pre-stroke
mm
4.8
4.74
4.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
143.6
141.6
145.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
141.1
138.1
144.1
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
9.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
143.4
140.4
146.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
9.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
148.5
142.5
154.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
9.1
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
123.4
117.4
129.4
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
F
Rack position
4.2+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
9.6
6.6
12.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
900
Advance angle
deg.
1.7
1.4
2
Load
3/4
Timer adjustment_02
Pump speed
r/min
1060
Advance angle
deg.
4.75
4.45
5.05
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Excess fuel setting for starting: SXL
(5)Set the damper spring (after setting the idle spring).
----------
RT=0.8 TH=2.7mm SXL=10.1+-0.1mm
----------
----------
RT=0.8 TH=2.7mm SXL=10.1+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=14deg+-5deg
----------
----------
a=14deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=42mm
----------
a=39deg+-5deg b=46deg+-3deg
----------
aa=42mm
----------
a=39deg+-5deg b=46deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Drive side
----------
----------
a=30deg+-5deg b=64deg+-5deg
----------
----------
a=30deg+-5deg b=64deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
Information:
2. Turn the crankshaft until two pistons are at bottom center.3. Remove nuts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rods from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.Install Pistons And Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. Some engines use pistons which have the word "FRONT" stamped on the crown of the piston. These pistons also have a green color code on the bottom surface of the side relief directly under the word "FRONT". Make sure the word "FRONT" and the color code are toward the front of the engine when the piston is installed.2. Use tool (A), and install piston (1) and the connecting rod in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft. Also, be sure the word "FRONT" on the crown of the piston is toward the front of the engine. 3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the nuts, and tighten them to a torque of 80 8 N m (60 6 lb.ft.). Put a mark on the nuts and cap, and tighten the nuts an extra 120°.5. Do Steps 1 through 4 for the remainder of the pistons.END BY:a. install oil pumpb. install cylinder head assemblyDisassemble And Assemble Pistons And Connecting Rod Assemblies
START BY:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to 500°F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of tooling (C). Put a new rod pin bearing (6) on the adapter part of tooling (C). The old bearing is pushed out by tooling (C) as the new bearing is installed.7. Use tooling (C) to push the new bearing into the connecting rod until the push adapter of tooling (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in.).9. Check the
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. Some engines use pistons which have the word "FRONT" stamped on the crown of the piston. These pistons also have a green color code on the bottom surface of the side relief directly under the word "FRONT". Make sure the word "FRONT" and the color code are toward the front of the engine when the piston is installed.2. Use tool (A), and install piston (1) and the connecting rod in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft. Also, be sure the word "FRONT" on the crown of the piston is toward the front of the engine. 3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the nuts, and tighten them to a torque of 80 8 N m (60 6 lb.ft.). Put a mark on the nuts and cap, and tighten the nuts an extra 120°.5. Do Steps 1 through 4 for the remainder of the pistons.END BY:a. install oil pumpb. install cylinder head assemblyDisassemble And Assemble Pistons And Connecting Rod Assemblies
START BY:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to 500°F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of tooling (C). Put a new rod pin bearing (6) on the adapter part of tooling (C). The old bearing is pushed out by tooling (C) as the new bearing is installed.7. Use tooling (C) to push the new bearing into the connecting rod until the push adapter of tooling (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in.).9. Check the
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