Information injection-pump assembly
ZEXEL
106651-0440
1066510440
Rating:
Service parts 106651-0440 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96501
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
106651-0440
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106651-0440
1066510440
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-4-2-6-
3-5
Pre-stroke
mm
3.65
3.6
3.7
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
A
Rack position
10.8
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
92.3
90.3
94.3
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.9+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
13.4
11.7
15.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Timer adjustment
Pump speed
r/min
300+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
1.35
0.7
1.6
Timer adjustment_03
Pump speed
r/min
700
Advance angle
deg.
2.85
2.1
3.1
Timer adjustment_04
Pump speed
r/min
900
Advance angle
deg.
4.4
3.6
4.6
Timer adjustment_05
Pump speed
r/min
1100+50
Advance angle
deg.
6.1
5.7
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Variable speed specification.
(2)Beginning of damper spring operation: DL
(3)Idle sub spring setting: L1.
(4)Rack limit using stop lever
----------
DL=5.9-0.2mm L1=6.6-0.2mm
----------
----------
DL=5.9-0.2mm L1=6.6-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=9deg+-5deg b=10deg+-5deg
----------
----------
a=9deg+-5deg b=10deg+-5deg
0000000901
F:Full load
(1)Fix using the stopper bolt.
----------
----------
a=20deg+-5deg
----------
----------
a=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1+0.5mm bb=11.5mm
----------
a=25deg+-5deg b=29.5deg+-3deg
----------
aa=1+0.5mm bb=11.5mm
----------
a=25deg+-5deg b=29.5deg+-3deg
0000001501 GOV FULL LOAD ADJUSTMENT
Title1:Full load stopper adjustment
Title2:Governor set speed
LABEL1:Distinguishing
LABEL2:Pump speed (r/min)
LABEL3:Ave. injection quantity (mm3/st)
LABEL4:Max. var. bet. cyl.
LABEL5:Remarks
LABEL6:Distinguishing
LABEL7:Governor set speed (r/min)
LABEL8:Maximum no-load speed (r/min)
LABEL9:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)At high idle rack position L
----------
L=5.6mm
----------
a1=A a2=B a3=C a4=D r1=750r/min r2=750r/min r3=750r/min r4=750r/min Q1=110.6+-2mm3/st Q2=98.3+-2mm3/st Q3=92.3+-2mm3/st Q4=75.3+-2mm3/st c1=+-4% c2=+-4% c3=+-4% c4=+-4% a5=A-23,B-23,C-23,D-23 a6=A-22,B-22,C-22,D-22 a7=A-21,B-21,C-21,D-21 a8=A-20,B-20,C-20,D-20 a9=A-19,B-19,C-19,D-19 a10=A-18,B-18,C-18,D-18 a11=A-17,B-17,C-17,D-17 a12=A-16,B-16,C-16,D-16 a13=- a14=- a15=- r5=1150r/min r6=1100r/min r7=1050r/min r8=1000r/min r9=950r/min r10=900r/min r11=850r/min r12=800r/min r13=- r14=- r15=- R5=1235+-28r/min R6=1180+-27r/min R7=1130+-26r/min R8=1075+-25r/min R9=1020+-23r/min R10=965+-22r/min R11=915+-22r/min R12=860+-20r/min R13=- R14=- R15=-
----------
L=5.6mm
----------
a1=A a2=B a3=C a4=D r1=750r/min r2=750r/min r3=750r/min r4=750r/min Q1=110.6+-2mm3/st Q2=98.3+-2mm3/st Q3=92.3+-2mm3/st Q4=75.3+-2mm3/st c1=+-4% c2=+-4% c3=+-4% c4=+-4% a5=A-23,B-23,C-23,D-23 a6=A-22,B-22,C-22,D-22 a7=A-21,B-21,C-21,D-21 a8=A-20,B-20,C-20,D-20 a9=A-19,B-19,C-19,D-19 a10=A-18,B-18,C-18,D-18 a11=A-17,B-17,C-17,D-17 a12=A-16,B-16,C-16,D-16 a13=- a14=- a15=- r5=1150r/min r6=1100r/min r7=1050r/min r8=1000r/min r9=950r/min r10=900r/min r11=850r/min r12=800r/min r13=- r14=- r15=- R5=1235+-28r/min R6=1180+-27r/min R7=1130+-26r/min R8=1075+-25r/min R9=1020+-23r/min R10=965+-22r/min R11=915+-22r/min R12=860+-20r/min R13=- R14=- R15=-
Information:
Disconnect batteries before performance of any service work.
Start By:a. remove vibration damper
The crankshaft front seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made.
1. Make at least three holes in seal (1) with a hammer and a sharp punch.2. Use Tool (A) to remove seal (1). 3. Install Tool (C) in the seal bore.4. Install Tool (B) between Tool (C) and wear sleeve (2). Turn Tool (B) until the Tool makes a dent (crease) in wear sleeve (2). Do this in three or more places until the wear sleeve is loose.5. Remove Tools (B) and (C), and remove wear sleeve (2) from the crankshaft.Install Crankshaft Front Seal & Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the front crankshaft seal and wear sleeve with Tool (A). Use the procedures with follows:a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any 6V1541 Quick Cure Primer or 9S3265 Retaining Compound get on the lip of the seal.b. Install locator (3) and bolts (4) on the crankshaft.c. Seal (1) and wear sleeve (2) must be installed dry.
Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (1) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until the inside surface of installer (5) comes in contact with locator (3).h. Remove Tool (D) from the crankshaft seal and wear sleeve. Tool (D) will install the seal and wear sleeve to the correct depth on the crankshaft.End By:a. install vibration damper