Information injection-pump assembly
ZEXEL
106651-2080
1066512080
Rating:
Service parts 106651-2080 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME056146
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106651-2080
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106651-2080
1066512080
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
131424-1520
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
1-5-3-6-
2-4
Pre-stroke
mm
5.1
5.05
5.15
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
11.8
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
134.4
131.4
137.4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.2+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
18.6
15.9
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.8)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
134.4
133.4
135.4
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11.8)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
133.4
129.4
137.4
Difference in delivery
mm3/st.
8
8
8
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
Injection quantity adjustment_05
Adjusting point
D
Rack position
R2(10.9)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
110.5
106.5
114.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
E
Rack position
12.5+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
120
160
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2(10.9)
Boost pressure
kPa
12
12
12
Boost pressure
mmHg
90
90
90
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.3
Boost pressure
kPa
24
22.7
25.3
Boost pressure
mmHg
180
170
190
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(11.8)
Boost pressure
kPa
38.7
32
45.4
Boost pressure
mmHg
290
240
340
Timer adjustment
Pump speed
r/min
850+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.8
0.3
1.3
Timer adjustment_03
Pump speed
r/min
950
Advance angle
deg.
1.7
1.2
2.2
Timer adjustment_04
Pump speed
r/min
1050
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
----------
DL=5.2-0.2mm
----------
----------
DL=5.2-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=4deg+-5deg
----------
----------
a=4deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=21.5deg+-5deg b=36deg+-3deg
----------
----------
a=21.5deg+-5deg b=36deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=5deg+-5deg b=48deg+-5deg
----------
----------
a=5deg+-5deg b=48deg+-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=310r/min Ra=6.2mm
----------
----------
N1=310r/min Ra=6.2mm
----------
Information:
1. Turn the engine counterclockwise (as seen from the flywheel end of the engine) with Tool (A) until the No. 1 piston is at top center (TC) on the compression stroke. Install the timing bolt. Install 6V-2112 Timing Pin through the hole in the injection pump housing. See the topic "Finding Top Center Compression Position for NO. 1 Piston" in SENR6577 Testing & Adjusting. Tool (B), 6V-2112 Timing Pin, replaces 6V-6019 Timing Pin. 2. Remove two bolts (1).3. Remove eleven bolts (2) and cover (3). 4. Remove four bolts (5), retainer (6) and automatic timing advance (4).Install Automatic Timing Advance
1. Install automatic timing advance (4). Install retainer (6) and four bolts (5).2. Tighten the bolts (5) with fingers until there is a small amount of friction (slight drag) between the retainer and automatic timing advance (4). This friction will hold the unit against the timing gears. This prevents play (backlash) when gears are turned to the correct position.3. Remove the timing bolt. Turn the flywheel until the timing pin will go into the groove in the injection pump camshaft.4. With the timing pin installed, turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 30 degrees. The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center (TC).5. Turn the flywheel in the direction of engine rotation until the No. 1 piston of the engine is on top center compression stroke. Then turn the timing bolt into the threaded hole in the flywheel.6. Tighten bolts (5) to 25 N m (20 lb ft). Then remove the timing pin from the injection pump housing.7. Tighten bolts (5) to 135 7 N m (100 5 lb ft). Then remove the timing bolt from the flywheel.8. Turn the crankshaft two complete revolutions and check the timing again to see that timing pin will go into the groove in the injection pump camshaft with bolt in flywheel.9. If timing is not correct, do the procedure of Steps 1 through 7 again. If the timing is correct, be sure to remove the timing pin and the timing bolt. 5. Install eleven bolts (2) and cover (3).6. Install two bolts (1). Disassemble Automatic Timing Advance
Start By:a. remove automatic timing advance 1. Remove flange assembly (1). 2. Remove two springs (2) and two weights (3) from drive gear assembly (4). 3. Remove two slides (5) from pistons (6).4. Separate drive gear assembly (4) from advance sleeve (7).Assemble Automatic Timing Advance
1. Put weights (3) in position in flange assembly (1) as shown.2. Install springs (2) in flange assembly (1). 4. Use 1P-008 General Purpose Lubricant to hold slides (5) in position on drive gear assembly (4). Install slides (5) on pistons (6).5. Install advance sleeve (7) to drive gear assembly (4). 6. Install drive gear assembly (4) on flange assembly (1). Make sure slides (5) fit in grooves of the weights.End By:a. install automatic timing advance
1. Install automatic timing advance (4). Install retainer (6) and four bolts (5).2. Tighten the bolts (5) with fingers until there is a small amount of friction (slight drag) between the retainer and automatic timing advance (4). This friction will hold the unit against the timing gears. This prevents play (backlash) when gears are turned to the correct position.3. Remove the timing bolt. Turn the flywheel until the timing pin will go into the groove in the injection pump camshaft.4. With the timing pin installed, turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 30 degrees. The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center (TC).5. Turn the flywheel in the direction of engine rotation until the No. 1 piston of the engine is on top center compression stroke. Then turn the timing bolt into the threaded hole in the flywheel.6. Tighten bolts (5) to 25 N m (20 lb ft). Then remove the timing pin from the injection pump housing.7. Tighten bolts (5) to 135 7 N m (100 5 lb ft). Then remove the timing bolt from the flywheel.8. Turn the crankshaft two complete revolutions and check the timing again to see that timing pin will go into the groove in the injection pump camshaft with bolt in flywheel.9. If timing is not correct, do the procedure of Steps 1 through 7 again. If the timing is correct, be sure to remove the timing pin and the timing bolt. 5. Install eleven bolts (2) and cover (3).6. Install two bolts (1). Disassemble Automatic Timing Advance
Start By:a. remove automatic timing advance 1. Remove flange assembly (1). 2. Remove two springs (2) and two weights (3) from drive gear assembly (4). 3. Remove two slides (5) from pistons (6).4. Separate drive gear assembly (4) from advance sleeve (7).Assemble Automatic Timing Advance
1. Put weights (3) in position in flange assembly (1) as shown.2. Install springs (2) in flange assembly (1). 4. Use 1P-008 General Purpose Lubricant to hold slides (5) in position on drive gear assembly (4). Install slides (5) on pistons (6).5. Install advance sleeve (7) to drive gear assembly (4). 6. Install drive gear assembly (4) on flange assembly (1). Make sure slides (5) fit in grooves of the weights.End By:a. install automatic timing advance