Information injection-pump assembly
ZEXEL
106671-0591
1066710591
Rating:
Service parts 106671-0591 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96520
12.
Open Pre:MPa(Kqf/cm2)
22.6{230}
15.
NOZZLE SET
Include in #1:
106671-0591
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-0591
1066710591
Zexel num
Bosch num
Firm num
Name
106671-0591
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
1-4-2-6-
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
11.6
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
154.8
152.8
156.8
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_02
Adjusting point
C
Rack position
10.4
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
117.4
115.4
119.4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
7.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
14.3
13.3
15.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
10.4
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
12.3+0.2
Boost pressure
kPa
16
16
16
Boost pressure
mmHg
120
120
120
Timer adjustment
Pump speed
r/min
1200--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
2
2
2
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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 stroke: BCL
(5)Rack limit using the stop lever: R1
(6)Damper spring setting
(7)Variable speed specification: idling adjustment
(8)Main spring setting
(9)Set idle sub-spring
(10)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
RT=1 TH=2.1mm BCL=2+-0.1mm R1=12.3+0.2mm
----------
----------
RT=1 TH=2.1mm BCL=2+-0.1mm R1=12.3+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
----------
aa=275r/min
----------
a=23deg+-5deg b=15deg+-5deg
----------
aa=275r/min
----------
a=23deg+-5deg b=15deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)At center of threaded hole above R = aa
----------
aa=17mm
----------
a=15deg+-5deg b=27deg+-3deg
----------
aa=17mm
----------
a=15deg+-5deg b=27deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
----------
aa=12.3+0.2mm
----------
a=30deg+-5deg b=32deg+-5deg
----------
aa=12.3+0.2mm
----------
a=30deg+-5deg b=32deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
start by: a) remove flywheel housingb) remove timing gear coverc) remove pistons 1. Turn the crankshaft until the "C" mark on crankshaft gear (2) is in alignment with the "C" mark on camshaft gear (1). 2. Put a mark across the teeth of the fuel pump drive gear and idler gear at location (X). Put a mark across the teeth of the idler gear and camshaft gear at location (Y). The marks are necessary for the correct timing of the camshaft for the fuel injection pump when the crankshaft is installed.3. Fasten a hoist to the crankshaft.4. Remove the caps for the crankshaft main bearings.5. Remove the crankshaft. Weight of the crankshaft is 200 lb. (91 kg).6. Remove the main bearings from the main bearing caps. Remove the crankshaft main bearings from the cylinder block. 7. Use tool (A) to remove the crankshaft gear and the oil seal wear sleeve.Install Crankshaft
1. Clean the bearing surfaces in the cylinder block. Install the upper halves of the main bearings in the block. Put clean SAE 30 engine oil on the bearings.2. Heat the crankshaft gear to a maximum temperature of 601°F (316°C). Install the gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all timing marks in alignment.3. Clean the bearing surfaces of the main bearing caps. Install the lower halves of the main bearings in the caps. 4. Install Plastigage (A) on the bearing to check the bearing clearance. See INSTALL CRANKSHAFT MAIN BEARINGS for the correct bearing clearance procedure. The main bearing caps must be installed with the part number toward the front of the block. Make sure the number on the cap is the same number as the number on the left side of each cap saddle. 5. Install thrust plate (1) (bearing) in the No. 7 main bearing. The thrust bearing has a tab that fits into a machined area in the cylinder block. The tab will not let the thrust bearing be installed backward.6. Put clean SAE 30 engine oil on the cap bolt threads, face of the washers and lower halves of the main bearings. Put the caps in position on the engine. Install the bolts and washers. Tighten the bolts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark across the bolt heads and bearing, and tighten the bolts 90° clockwise from the mark. 7. Check the crankshaft end play with tool group (B). End play with new bearings must be .0025 to .0145 in. (0.064 to 0.368 mm). Maximum permissible end play with used bearings is .025 in. (0.64 mm). The crankshaft end play is controlled by the thrust plates (bearings).8. If the fuel pump drive gear, idler gear, or camshaft gear has been removed or if a replacement of the crankshaft gear has been made, it will be necessary to put the engine into time after assembly. See INSTALL FUEL INJECTION PUMP
1. Clean the bearing surfaces in the cylinder block. Install the upper halves of the main bearings in the block. Put clean SAE 30 engine oil on the bearings.2. Heat the crankshaft gear to a maximum temperature of 601°F (316°C). Install the gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all timing marks in alignment.3. Clean the bearing surfaces of the main bearing caps. Install the lower halves of the main bearings in the caps. 4. Install Plastigage (A) on the bearing to check the bearing clearance. See INSTALL CRANKSHAFT MAIN BEARINGS for the correct bearing clearance procedure. The main bearing caps must be installed with the part number toward the front of the block. Make sure the number on the cap is the same number as the number on the left side of each cap saddle. 5. Install thrust plate (1) (bearing) in the No. 7 main bearing. The thrust bearing has a tab that fits into a machined area in the cylinder block. The tab will not let the thrust bearing be installed backward.6. Put clean SAE 30 engine oil on the cap bolt threads, face of the washers and lower halves of the main bearings. Put the caps in position on the engine. Install the bolts and washers. Tighten the bolts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark across the bolt heads and bearing, and tighten the bolts 90° clockwise from the mark. 7. Check the crankshaft end play with tool group (B). End play with new bearings must be .0025 to .0145 in. (0.064 to 0.368 mm). Maximum permissible end play with used bearings is .025 in. (0.64 mm). The crankshaft end play is controlled by the thrust plates (bearings).8. If the fuel pump drive gear, idler gear, or camshaft gear has been removed or if a replacement of the crankshaft gear has been made, it will be necessary to put the engine into time after assembly. See INSTALL FUEL INJECTION PUMP
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106671-0591
INJECTION-PUMP ASSEMBLY