Information injection-pump assembly
ZEXEL
106671-9183
1066719183
Rating:
Cross reference number
ZEXEL
106671-9183
1066719183
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
134424-1420
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
4
3.94
4
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.7
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
130
128
132
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
11
9
13
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
120
130
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R1(8.8)
Boost pressure
kPa
22.7
22.7
22.7
Boost pressure
mmHg
170
170
170
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R1+0.45
Boost pressure
kPa
28.7
28
29.4
Boost pressure
mmHg
215
210
220
Boost compensator adjustment_03
Pump speed
r/min
550
550
550
Rack position
(9.7)
Boost pressure
kPa
40
40
40
Boost pressure
mmHg
300
300
300
Timer adjustment
Pump speed
r/min
1000--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
950
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1150
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
(3)Boost compensator cancel stroke: BSL
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Damper spring setting
(7)Rack difference between N = N3 and N = N4
----------
N1=300r/min R1=6.4mm N2=1150r/min Q1=3mm3/st BSL=2.2mm BCL=(0.9)mm N3=1150r/min N4=700r/min
----------
----------
N1=300r/min R1=6.4mm N2=1150r/min Q1=3mm3/st BSL=2.2mm BCL=(0.9)mm N3=1150r/min N4=700r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=(7deg)+-5deg
----------
----------
a=(7deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=65mm
----------
a=22deg+-5deg b=24.5deg+-3deg
----------
aa=65mm
----------
a=22deg+-5deg b=24.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=30mm
----------
a=64deg+-5deg b=44deg+-5deg
----------
aa=30mm
----------
a=64deg+-5deg b=44deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine.Before operating the machine, place the steering frame lock in the stored position.Failure to place the steering frame lock into the stored position before operating can result in loss of steering.
Reference: Disassembly and Assembly, M0084637, "R1700 Load Haul Dump Machine Systems"Reference: Disassembly and Assembly, M0100022, "R2900 Load Haul Dump Machine Systems"Required Parts
Table 1
Required Parts
Qty Part Number Description
1 389-9442 Insulation
1 434-1304 Insulation
1 434-1305 Insulation
7 290-1993 Cable Strap Machine Preparation
Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.
Move the machine to a hard level surface away from operating machines and away from personnel.
Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
Stop the engine.
Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Install".
Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.
Release system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".Procedure
Illustration 1 g06525155
Typical example
(1) Cover As
(2) Cover As
Remove cover assembly (1) and cover assembly (2).
Illustration 2 g06525163
Typical example
(3) Hose As
Locate DEF supply hose assembly (3).
Illustration 3 g06526653
DEF supply hose on the R1700 machine
(4) 290-1993 Cable Strap
(5) 389-9442 Insulation
(6) 434-1305 Insulation
(7) 434-1304 Insulation
Illustration 4 g06526655
DEF supply hose on the R2900 machine
(4) 290-1993 Cable Strap
(5) 389-9442 Insulation
(6) 434-1305 Insulation
(7) 434-1304 Insulation
Install Item (5) through Item (7), securing with 290-1993 Cable Straps as required.Note: On the R1700 machine, 434-1305 Insulation (6) is installed over the top of 389-9442 Insulation (5).Note: On the R2900 machine, 434-1305 Insulation (6) slightly overlaps 389-9442 Insulation (5).
Install cover assembly (1) and cover assembly (2). Refer to Illustration 1.