Information injection-pump assembly
ZEXEL
101607-6891
1016076891
Rating:
Service parts 101607-6891 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME075761
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
101607-6891
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-5110
as _
Cross reference number
ZEXEL
101607-6891
1016076891
Zexel num
Bosch num
Firm num
Name
101607-6891
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
131424-8420
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.9
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
86.5
83.9
89.1
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.5+-0.5
Pump speed
r/min
600
600
600
Each cylinder's injection qty
mm3/st.
10.8
9.2
12.4
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.9)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
86.5
85.5
87.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.35
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
90.5
86.5
94.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
71.5
67.5
75.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
95
85
105
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1
0.5
1.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
1
0.5
1.5
Timer adjustment_05
Pump speed
r/min
1400
Advance angle
deg.
7
6.5
7.5
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
----------
T1=K60
----------
----------
T1=K60
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=41deg+-5deg b=42deg+-3deg
----------
aa=35mm
----------
a=41deg+-5deg b=42deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm
----------
a=32.5deg+-5deg b=25deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm
----------
a=32.5deg+-5deg b=25deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------
----------
N1=400r/min Ra=9.2+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=7deg
----------
a=(3deg)
----------
aa=7deg
----------
a=(3deg)
Information:
Illustration 21 shows the direction the rack moves when the fuel injector is receiving fuel.
Illustration 22 g01455811
Illustration 1 - Flowchart for the Air in Fuel Test (Test F)
Illustration 23 g01455812
Illustration 2 - Flowchart for the Air in Fuel Test (Test F)Fuel Injector Cranking Test (Test G)
Note: The fuel injector cranking test checks for worn out injectors by measuring the cranking rack.
Illustration 24 g01412134
(3) The rack control (4) The number one fuel injectorNote: Refer to Illustration 24 for the location of the rack control and the location of the number one injector.
Illustration 25 g01412115
Flowchart for the Fuel Injector Cranking Test (Test G)Fuel Shutoff Solenoid Test (Test H)
Note: The fuel shutoff solenoid test determines if the fuel shutoff solenoid and wiring harness are operating properly.
Illustration 26 g01412143
Flowchart for the Fuel Shutoff Solenoid Test (Test H)Fuel Ratio Control (FRC) Setting Test (Test I)
Note: The FRC setting test checks the FRC setting.
Illustration 27 g01412145
Flowchart for the Fuel Ratio Control (FRC) Setting Test (Test I)Governor Servo Retaining Ring Test (Test J)
Note: Do not run the engine during this test.Note: The governor servo retaining ring test checks for faulty internal parts of the governor.
Illustration 28 g01422811
(1) Paddle
Illustration 29 g01422821
(2) Clevis pin
Illustration 30 g01412147
Flowchart for the Governor Servo Retaining Ring Test (Test J)Fuel Transfer Pump Test (Test K)
Note: The fuel transfer pump test is a visual inspection of the fuel transfer pump components.
Illustration 31 g01412150
(1) Screen (2) Inlet check valve (3) Spring (4) Bolt (5) Piston (6) Outlet check valve (7) Freeze plug (8) Piston check valve (9) Passage (10) Tappet Assembly (11) CamNote: Refer to Illustration 31 for the location of the components for the fuel transfer pump.
Illustration 32 g01412149
Flowchart for the Fuel Transfer Pump Test (Test K)Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)
Note: The FRC diaphragm leak test checks for a leaking FRC diaphragm.
Illustration 33 g01412154
Flowchart for the Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)
Illustration 22 g01455811
Illustration 1 - Flowchart for the Air in Fuel Test (Test F)
Illustration 23 g01455812
Illustration 2 - Flowchart for the Air in Fuel Test (Test F)Fuel Injector Cranking Test (Test G)
Note: The fuel injector cranking test checks for worn out injectors by measuring the cranking rack.
Illustration 24 g01412134
(3) The rack control (4) The number one fuel injectorNote: Refer to Illustration 24 for the location of the rack control and the location of the number one injector.
Illustration 25 g01412115
Flowchart for the Fuel Injector Cranking Test (Test G)Fuel Shutoff Solenoid Test (Test H)
Note: The fuel shutoff solenoid test determines if the fuel shutoff solenoid and wiring harness are operating properly.
Illustration 26 g01412143
Flowchart for the Fuel Shutoff Solenoid Test (Test H)Fuel Ratio Control (FRC) Setting Test (Test I)
Note: The FRC setting test checks the FRC setting.
Illustration 27 g01412145
Flowchart for the Fuel Ratio Control (FRC) Setting Test (Test I)Governor Servo Retaining Ring Test (Test J)
Note: Do not run the engine during this test.Note: The governor servo retaining ring test checks for faulty internal parts of the governor.
Illustration 28 g01422811
(1) Paddle
Illustration 29 g01422821
(2) Clevis pin
Illustration 30 g01412147
Flowchart for the Governor Servo Retaining Ring Test (Test J)Fuel Transfer Pump Test (Test K)
Note: The fuel transfer pump test is a visual inspection of the fuel transfer pump components.
Illustration 31 g01412150
(1) Screen (2) Inlet check valve (3) Spring (4) Bolt (5) Piston (6) Outlet check valve (7) Freeze plug (8) Piston check valve (9) Passage (10) Tappet Assembly (11) CamNote: Refer to Illustration 31 for the location of the components for the fuel transfer pump.
Illustration 32 g01412149
Flowchart for the Fuel Transfer Pump Test (Test K)Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)
Note: The FRC diaphragm leak test checks for a leaking FRC diaphragm.
Illustration 33 g01412154
Flowchart for the Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)
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101607-6891
INJECTION-PUMP ASSEMBLY