Information injection-pump assembly
ZEXEL
101607-6950
1016076950
Rating:
Cross reference number
ZEXEL
101607-6950
1016076950
Zexel num
Bosch num
Firm num
Name
101607-6950
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
131424-5520
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
2.95
3.05
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
A
Rack position
9.7
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
84
83
85
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
17.2
14.6
19.8
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
1050--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Supplied with torque spring not set.
(4)Set idle sub-spring
(5)Main spring setting
(6)Set at delivery
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Set at delivery
----------
----------
a=(31deg)+-5deg b=(2deg) c=(24deg)+-5deg
----------
----------
a=(31deg)+-5deg b=(2deg) c=(24deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26deg+-5deg b=53deg+-5deg
----------
----------
a=26deg+-5deg b=53deg+-5deg
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=14deg
----------
a=(1deg)
----------
aa=14deg
----------
a=(1deg)
Information:
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Affected Engines
This Special Instruction provides the proper instructions on accessing the timing hole for high pressure fuel pumps on C7 Engines. The procedure is for the C7 Engines that are in General Motors and Blue Bird chassis. The timing hole may need to be accessed after the high pressure fuel injection pump is replaced in order to time the new high pressure pump.Disassembly Procedure
Illustration 1 g01458243
(1) Clean Gas Induction (CGI) Cooler (2) Aftertreatment Regeneration Device (ARD) Housing Bracket (3) Timing Hole Plug (4) Aftertreatment Regeneration Device (ARD) Housing
Illustration 2 g01458244
(5) Mounting bolts for the bracket for the ARD housing
Remove the two mounting bolts (5) from the bracket for the housing for the ARD. Use a 18 millimeter socket in order to loosen the mounting bolts. Make sure that the socket can flex. Also use a 12 inch socket extension in order to loosen the mounting bolts. After the bolts have been broken loose the bolts must be turned by hand in order to finish removing the bolts.
Illustration 3 g01458245
(6) Exhaust clamp for the ARD
Loosen the exhaust clamp (6) for the ARD. Slide the exhaust clamp down the exhaust pipe. Do not remove the clamp completely. This may cause the clamp to become bent. This may cause the clamp to not fit properly.
Illustration 4 g01458247
(7) Timing hole for the high pressure fuel pump
Move the housing bracket for the ARD to the side. This will provide enough clearance in order to remove the plug from the timing hole.The timing hole can be used to check the timing for the fuel injection pump. If the fuel injection pump needs to be timed properly then refer to Disassembly and Assembly, RENR9707, "Fuel Injection Pump - Install" for the proper installation procedure to ensure the the fuel injection pump will be timed properly.Assembly Procedure
Illustration 5 g01458476
(3) Timing hole plug
Reinstall the timing hole plug (3) back into the timing hole.
Illustration 6 g01458245
(6) Exhaust clamp for the ARD
Reinstall the exhaust clamp (6) for the ARD.
Illustration 7 g01458244
(5) Mounting bolts for the housing bracket for the ARD
Move the bracket for the ARD into the original position. Reinstall the mounting bolts (5) for the mounting bracket for the ARD.
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Affected Engines
This Special Instruction provides the proper instructions on accessing the timing hole for high pressure fuel pumps on C7 Engines. The procedure is for the C7 Engines that are in General Motors and Blue Bird chassis. The timing hole may need to be accessed after the high pressure fuel injection pump is replaced in order to time the new high pressure pump.Disassembly Procedure
Illustration 1 g01458243
(1) Clean Gas Induction (CGI) Cooler (2) Aftertreatment Regeneration Device (ARD) Housing Bracket (3) Timing Hole Plug (4) Aftertreatment Regeneration Device (ARD) Housing
Illustration 2 g01458244
(5) Mounting bolts for the bracket for the ARD housing
Remove the two mounting bolts (5) from the bracket for the housing for the ARD. Use a 18 millimeter socket in order to loosen the mounting bolts. Make sure that the socket can flex. Also use a 12 inch socket extension in order to loosen the mounting bolts. After the bolts have been broken loose the bolts must be turned by hand in order to finish removing the bolts.
Illustration 3 g01458245
(6) Exhaust clamp for the ARD
Loosen the exhaust clamp (6) for the ARD. Slide the exhaust clamp down the exhaust pipe. Do not remove the clamp completely. This may cause the clamp to become bent. This may cause the clamp to not fit properly.
Illustration 4 g01458247
(7) Timing hole for the high pressure fuel pump
Move the housing bracket for the ARD to the side. This will provide enough clearance in order to remove the plug from the timing hole.The timing hole can be used to check the timing for the fuel injection pump. If the fuel injection pump needs to be timed properly then refer to Disassembly and Assembly, RENR9707, "Fuel Injection Pump - Install" for the proper installation procedure to ensure the the fuel injection pump will be timed properly.Assembly Procedure
Illustration 5 g01458476
(3) Timing hole plug
Reinstall the timing hole plug (3) back into the timing hole.
Illustration 6 g01458245
(6) Exhaust clamp for the ARD
Reinstall the exhaust clamp (6) for the ARD.
Illustration 7 g01458244
(5) Mounting bolts for the housing bracket for the ARD
Move the bracket for the ARD into the original position. Reinstall the mounting bolts (5) for the mounting bracket for the ARD.
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101607-6950
INJECTION-PUMP ASSEMBLY