Information injection-pump assembly
ZEXEL
106651-4020
1066514020
Rating:
Service parts 106651-4020 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106651-4020
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106651-4020
1066514020
Zexel num
Bosch num
Firm num
Name
106651-4020
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 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
1-5-3-6-
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
12.1
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
140
136.5
143.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
225
225
225
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(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
140
139
141
Basic
*
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.1)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
135
143
Difference in delivery
mm3/st.
8
8
8
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_05
Adjusting point
D
Rack position
11.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
121
117.4
124.6
Fixing the lever
*
Boost pressure
kPa
26
26
26
Boost pressure
mmHg
195
195
195
Injection quantity adjustment_06
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
90
130
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
10.4
Boost pressure
kPa
5.3
5.3
5.3
Boost pressure
mmHg
40
40
40
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.5
Boost pressure
kPa
26
24.7
27.3
Boost pressure
mmHg
195
185
205
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(12.1)
Boost pressure
kPa
38
31.3
44.7
Boost pressure
mmHg
285
235
335
Timer adjustment
Pump speed
r/min
450--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
720
Advance angle
deg.
2.5
2
3
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Boost compensator cancel stroke: BSL
(5)Boost compensator stroke
(6)Damper spring setting
----------
RT=1 TH=2.8mm BSL=2mm
----------
----------
RT=1 TH=2.8mm BSL=2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=9deg+-5deg
----------
----------
a=9deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=31deg+-5deg b=36.5deg+-3deg
----------
----------
a=31deg+-5deg b=36.5deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Rack position = bb, set the stopper bolt.
(3)Free (at delivery)
----------
aa=14mm bb=4.9-0.5mm
----------
a=(35.5deg) b=25.5deg+-5deg c=0deg+7deg-5deg
----------
aa=14mm bb=4.9-0.5mm
----------
a=(35.5deg) b=25.5deg+-5deg c=0deg+7deg-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=325r/min Ra=6+-0.1mm
----------
----------
N1=325r/min Ra=6+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(6deg)
----------
----------
a=(6deg)
Information:
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Diesel Exhaust Fluid Pressure Line Removal Process:
1. Follow the Disassembly and Assembly, UENR4468, for Diesel Exhaust Fluid Lines ? Remove and Install, steps 1 to 9 to remove the DEF pressure line.
2. Remove p-clips (3) and (4) on the plate attached to the hydraulic tank and on the sound wall support leg. Keep the bolt and washer from p-clip (4) as it will be used to install the new pressure line (Image1.1.1).
Image1.1.1
3. Remove p-clip (8) from the inside of the frame and p-clips (10,12) inside of the DEF enclosure from the diesel exhaust fluid pressure line (11) (Image1.2.1).
4. Cut cable ties (9,13) near the PETU from the diesel exhaust fluid pressure line (11) (Image1.2.1).
5. Pull the diesel exhaust fluid pressure line (11) out of the machine (Image1.2.1).
Image1.2.1
DEF Injector Replacement ? Remove and Install:
1. Remove DEF injector and replace. Follow Disassembly and Assembly, UENR6559, for DEF Injector and Mounting - Remove and Install.
New Diesel Exhaust Fluid Pressure Line Preparation:
1. Lay the 3.65 m pressure line out straight on a flat surface
2. Measure 308 mm from the mating point of the line and the connector and mark the location
3. Measure 631 mm from the mating point of the line and the connector and mark the location
4. Measure 996 mm from the mating point of the line and the connector and mark the location
5. Measure 1386 mm from the mating point of the line and the connector and mark the location
6. Place p-clip (6D-4246) on the line with its edge on the 1st mark
7. Place p-clip (336-8614) on the line with its edge on the 2nd mark
8. Place p-clip (336-8614) on the line with its edge on the 3rd mark
9. Place p-clip (336-8614) on the line with its edge on the 4th mark
Note: Keep lines capped when measuring and placing the p-clips
Image1.4.1
Machine Preparation:
1. Remove bracket (1) from machine. Keep the bolt and washer as it will be used when installing the new pressure line (Image1.5.1).
2. Drill an 11 mm diameter hole in the hood support. Refer to Image1.5.2 for location and Image1.5.3 for dimensions.
3. Remove the bolt and washer on the hydraulic tank support plate and keep as it will be used when installing the new diesel exhaust fluid pressure line (Image1.5.4).
Image1.5.1
Image1.5.2
Image1.5.3
Image1.5.4
Installation Process:
1. Remove plugs from the new diesel exhaust fluid pressure line
2. Attach p-clip 6D-4246 (1) and hose to the newly drilled 11 mm hole in the hood support using hardware nut 344-5675 (qty. 1), washer 8T-4121 (qty. 2), and bolt 8T-4195 (qty. 1). Once attached, the p-clip should be oriented at 15 degrees from vertical pointing downwards. Torque hardware to 55 Nm (Image1.6.1).
Image1.6.1
3. Attach p-clip 336-8614 (2) to the hydraulic tank and secure using the removed hardware (bolt: 8T-4136 and washer: 7X-7729) from step 3 of the machine preparation. Once attached, the p-clip should be oriented at 30 degrees from vertical pointing upwards to maintain the upwards slope of the line towards the hydraulic tank. Torque hardware to 55 Nm once p-clip is oriented correctly (Image1.7.1.).
Image1.7.1
4. Connect the diesel exhaust fluid line to the DEF injector
5. Attach
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106651-4020
INJECTION-PUMP ASSEMBLY