Information injection-pump assembly
ZEXEL
106671-7571
1066717571
Rating:
Service parts 106671-7571 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME056357
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106671-7571
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-7571
1066717571
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
131424-6920
Overflow valve opening pressure
kPa
191
157
225
Overflow valve opening pressure
kgf/cm2
1.95
1.6
2.3
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
4.8
4.75
4.85
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
9.3
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
144
140.5
147.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
F
Rack position
5+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
144
143
145
Basic
*
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Injection quantity adjustment_04
Adjusting point
B
Rack position
9.65+-0.
5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
161
159
163
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Injection quantity adjustment_05
Adjusting point
C
Rack position
5.5+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
(check)
(check)
Injection quantity adjustment_06
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
130
110
150
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
G
Rack position
9.8+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
153
151
155
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
8.1
Boost pressure
kPa
4
4
4
Boost pressure
mmHg
30
30
30
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1-0.7
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(9.3)
Boost pressure
kPa
14.7
14.7
14.7
Boost pressure
mmHg
110
110
110
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Boost compensator cancel stroke: BSL
(2)Boost compensator stroke
(3)Damper spring setting: DL
----------
BSL=1.2mm DL=4.1-0.2mm
----------
----------
BSL=1.2mm DL=4.1-0.2mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=16.5deg+-5deg
----------
----------
a=16.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=28deg+-5deg b=(30deg)+-3deg
----------
----------
a=28deg+-5deg b=(30deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at shipping)
----------
aa=4.1-0.5mm bb=13.3mm
----------
a=26deg+-5deg b=(38deg) c=0deg+7deg-5deg
----------
aa=4.1-0.5mm bb=13.3mm
----------
a=26deg+-5deg b=(38deg) 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=325+-5r/min Ra=5.2mm
----------
----------
N1=325+-5r/min Ra=5.2mm
----------
0000001601 RACK SENSOR
V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(7deg)
----------
----------
a=(7deg)
Information:
Table 1
Part Number Part Description Qty
378-3187 Diesel Exhaust Fluid Filter Gp 1
423-3251 Connector 1
391-5262 Gasket 1
425-0385 Filter As 1
452-6055 Filter Base As 1
453-1604(1) Diesel Exhaust Fluid Filter Gp 1
453-1605(1) Diesel Exhaust Fluid Filter Gp 1
453-1606(1) Diesel Exhaust Fluid Filter Gp 1
(1) Use Table 2 to choose the correct part that corresponds to the DEF heater
Table 2
DEF Heater Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 The effective serial numbers for this change are related to the Pump Electronic Tank Unit (PETU) serial numbers and not the machine serial numbers. Table 3 contains the effective serial numbers for the PETU tank. Refer to illustration 1 and illustration 2 for examples of where to locate the PETU serial number.
Illustration 1 g06018843
Typical example
(1) The location of the PETU serial plate.
Illustration 2 g03418749
Typical example
Table 3
PETU Effective Serial Numbers
S/N:PET007086T-UP Refer to Special Instruction, M0066142, A New Diesel Exhaust Fluid Filter is Now Available for C7.1 Engines for installation instructions.