Information injection-pump assembly
ZEXEL
106651-0480
1066510480
Rating:
Service parts 106651-0480 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96001
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
106651-0480
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106651-0480
1066510480
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
11
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
108.6
107.6
109.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.6
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
81
79.5
82.5
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
15
13.9
16.1
Max. variation between cylinders
%
0
-15
15
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
-
Advance angle
deg.
6.1
6.1
6.1
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Idle sub spring setting: L1.
----------
K=12 RAL=14+-0.1mm L1=7-0.5mm
----------
----------
K=12 RAL=14+-0.1mm L1=7-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Speed set at aa (setting at shipping)
(2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=20deg+-5deg b=8deg+-5deg c=32deg+-3deg d=5deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=20deg+-5deg b=8deg+-5deg c=32deg+-3deg d=5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26deg+-5deg b=53deg+-5deg
----------
----------
a=26deg+-5deg b=53deg+-5deg
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:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)-
----------
----------
a1=B a2=A r1=750r/min r2=750r/min Q1=102.4+-1mm3/st Q2=108.6+-1mm3/st c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min
----------
----------
a1=B a2=A r1=750r/min r2=750r/min Q1=102.4+-1mm3/st Q2=108.6+-1mm3/st c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min
Information:
Start By:a. remove valve covers
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turns in the body.
1. Loosen the fuel injection line nut at the nozzle end with tool (A) and a 7/8 5P0328 ( in) Crow Foot Wrench.2. Loosen the fuel line nut at the fuel injection line adapter with Tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system.
Typical Example If necessary, use Tool (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with Tool (C) to remove the push rods.3. Put compression on the valve springs with Tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the intake valve lifter with Tool (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5).b. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5).
Typical Examplec. Install Tool (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of the intake valve lifter.
Typical Exampled. Remove intake valve lifters (7) from the cylinder block with Tool (E). Put identification marks on the lifters as to their location in the engine.
Typical Example6. Remove the exhaust valve lifters with Tool (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5). The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side.b. Install the outer handle assembly in the intake valve lifter side of the cylinder head assembly. Slide the flat area of 5P2408 Outer Handle Assembly (5) through the head casting and install the 5P6601 Collet in the exhaust valve lifters.
Typical Examplec. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). Hold the 5P2408 Handle Assembly and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e. Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting and remove it from the intake valve lifter side of the cylinder head.
Typical Examplef. Use a magnet and remove exhaust valve lifters (8) from the intake valve lifter side of the cylinder head assembly. Put identification makes on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turns in the body.
1. Loosen the fuel injection line nut at the nozzle end with tool (A) and a 7/8 5P0328 ( in) Crow Foot Wrench.2. Loosen the fuel line nut at the fuel injection line adapter with Tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system.
Typical Example If necessary, use Tool (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with Tool (C) to remove the push rods.3. Put compression on the valve springs with Tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the intake valve lifter with Tool (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5).b. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5).
Typical Examplec. Install Tool (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of the intake valve lifter.
Typical Exampled. Remove intake valve lifters (7) from the cylinder block with Tool (E). Put identification marks on the lifters as to their location in the engine.
Typical Example6. Remove the exhaust valve lifters with Tool (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5). The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side.b. Install the outer handle assembly in the intake valve lifter side of the cylinder head assembly. Slide the flat area of 5P2408 Outer Handle Assembly (5) through the head casting and install the 5P6601 Collet in the exhaust valve lifters.
Typical Examplec. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). Hold the 5P2408 Handle Assembly and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e. Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting and remove it from the intake valve lifter side of the cylinder head.
Typical Examplef. Use a magnet and remove exhaust valve lifters (8) from the intake valve lifter side of the cylinder head assembly. Put identification makes on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve