Information injection-pump assembly
ZEXEL
106671-4110
1066714110
Rating:
Service parts 106671-4110 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
106671-4110
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-4110
1066714110
Zexel num
Bosch num
Firm num
Name
106671-4110
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
132424-0620
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
3
2.95
3.05
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
A
Rack position
10.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
159.2
154.4
164
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.8+-0.5
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
27
24.8
29.2
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
120
120
120
Average injection quantity
mm3/st.
184
184
214
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
800
Advance angle
deg.
2.2
1.7
2.7
Timer adjustment_04
Pump speed
r/min
1000
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
----------
K=13
----------
----------
K=13
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=11deg+-5deg b=31deg+-5deg c=54deg+-3deg
----------
----------
a=11deg+-5deg b=31deg+-5deg c=54deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=53deg+-5deg
----------
----------
a=20deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
Under the Hood Inspection
For maximum service life of your truck engine, make a thorough under the hood inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn belts and trash build-up. Remove trash build-up and have repairs made as needed.Perform required Daily maintenance before starting the engine.
Each time any significant quantity of oil (or other fluid) is spilled on or near the engine it should be cleaned up. Accumulated grease and oil on an engine is a fire hazard. Remove this debris with steam cleaning or high pressure water at PM Level 2 or every 6000 hours.Wipe clean all fittings, caps and plugs before servicing.
Starting the Engine
Do not store starting fluid containers in the cab. Failure to do so, could result in an explosion and/or fire and possible personal injury.If equipped with an electrically or fuel ignited manifold heater, DO NOT use ether.
Startability will be improved at temperatures below +32°F (0°C) by the use of a starting aid (ether) or use of a cylinder block coolant heater or other means to heat the crankcase oil. This will help alleviate white smoke and misfire during cold weather start-up.Use ether when temperatures are below 32°F (0°C) for cold weather starting purposes only.
When using starting fluid, follow the manufacturer's instructions carefully, use it sparingly and spray it ONLY WHILE CRANKING THE ENGINE. Excessive ether can cause piston and ring damage.Use ether for cold starting purposes only.
If the engine fails to start within 30 seconds, release the starter switch and wait two minutes to allow the starter motor to cool before using it again.Start the engine using the following procedure:1. Place the transmission in NEUTRAL and disengage the flywheel clutch (if equipped) to remove the transmission drag and prevent movement of the truck.Depressing the clutch in cold weather can mean the difference between starting and not starting. Depressing the clutch in warm weather produces faster starts and reduces battery drain.2. Turn the ignition switch to the ON position and push the crank button or turn the ignition switch to the START position.3. Crank the engine. If the engine fails to start in 30 seconds, release the starting (ignition) switch and wait two minutes to allow the starter motor to cool before using it again.
Do not increase engine speed until the oil pressure gauge indicates normal. Oil pressure should raise within 15 seconds after the engine starts.If oil pressure is not indicated on gauge within 15 seconds, do not drive the truck. Stop the engine, investigate and correct the cause.
4. Allow the engine to idle three to five minutes, or until the water temperature gauge has begun to rise. Check all gauges during the warm-up period.5. Check fuel level gauge. Do not fill fuel tank to top. Fuel expands as it gets warm and may overflow.Starting With Jumper Cables
When boost starting an engine, follow the instructions to properly start the engine. This engine may be equipped with a 12 or 24 volt starting system. Use only
For maximum service life of your truck engine, make a thorough under the hood inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn belts and trash build-up. Remove trash build-up and have repairs made as needed.Perform required Daily maintenance before starting the engine.
Each time any significant quantity of oil (or other fluid) is spilled on or near the engine it should be cleaned up. Accumulated grease and oil on an engine is a fire hazard. Remove this debris with steam cleaning or high pressure water at PM Level 2 or every 6000 hours.Wipe clean all fittings, caps and plugs before servicing.
Starting the Engine
Do not store starting fluid containers in the cab. Failure to do so, could result in an explosion and/or fire and possible personal injury.If equipped with an electrically or fuel ignited manifold heater, DO NOT use ether.
Startability will be improved at temperatures below +32°F (0°C) by the use of a starting aid (ether) or use of a cylinder block coolant heater or other means to heat the crankcase oil. This will help alleviate white smoke and misfire during cold weather start-up.Use ether when temperatures are below 32°F (0°C) for cold weather starting purposes only.
When using starting fluid, follow the manufacturer's instructions carefully, use it sparingly and spray it ONLY WHILE CRANKING THE ENGINE. Excessive ether can cause piston and ring damage.Use ether for cold starting purposes only.
If the engine fails to start within 30 seconds, release the starter switch and wait two minutes to allow the starter motor to cool before using it again.Start the engine using the following procedure:1. Place the transmission in NEUTRAL and disengage the flywheel clutch (if equipped) to remove the transmission drag and prevent movement of the truck.Depressing the clutch in cold weather can mean the difference between starting and not starting. Depressing the clutch in warm weather produces faster starts and reduces battery drain.2. Turn the ignition switch to the ON position and push the crank button or turn the ignition switch to the START position.3. Crank the engine. If the engine fails to start in 30 seconds, release the starting (ignition) switch and wait two minutes to allow the starter motor to cool before using it again.
Do not increase engine speed until the oil pressure gauge indicates normal. Oil pressure should raise within 15 seconds after the engine starts.If oil pressure is not indicated on gauge within 15 seconds, do not drive the truck. Stop the engine, investigate and correct the cause.
4. Allow the engine to idle three to five minutes, or until the water temperature gauge has begun to rise. Check all gauges during the warm-up period.5. Check fuel level gauge. Do not fill fuel tank to top. Fuel expands as it gets warm and may overflow.Starting With Jumper Cables
When boost starting an engine, follow the instructions to properly start the engine. This engine may be equipped with a 12 or 24 volt starting system. Use only
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106671-4110
INJECTION-PUMP ASSEMBLY