Information injection-pump assembly
ZEXEL
106675-4451
1066754451
Rating:
Cross reference number
ZEXEL
106675-4451
1066754451
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
131424-4420
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
4.3
4.25
4.35
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
10.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
145
143
147
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.9+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
15.5
14
17
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
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
146
146
156
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-1.6
Boost pressure
kPa
13.3
11.3
15.3
Boost pressure
mmHg
100
85
115
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1-1
Boost pressure
kPa
32
28
36
Boost pressure
mmHg
240
210
270
Boost compensator adjustment_03
Pump speed
r/min
500
500
500
Rack position
R1(10.8)
Boost pressure
kPa
66.7
66.7
66.7
Boost pressure
mmHg
500
500
500
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Deliver without the torque control spring operating.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Set idle sub-spring
----------
K=7 BCL=1.6+-0.1mm
----------
----------
K=7 BCL=1.6+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=27deg+-5deg
----------
----------
a=10deg+-5deg b=27deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=70deg+-5deg
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=70deg+-5deg
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Illustration 62 g02807941
Remove the plug
Remove plug (2) .
Illustration 63 g02807956
Set speed by turning adjusting screw
Adjust speed. If Ng exceeds TMI specifications, tighten the adjusting screw. If Ng is less than the specified value, loosen the adjusting screw.
Illustration 64 g02807957
Adjust the maximum-speed stopper bolt
Adjust the maximum-speed stopper bolt until the speed at the start of high-speed control is Nf.
Check that the no-load maximum speed is Ng (described in Step 1). Continue adjustment until the specified value is obtained.
Illustration 65 g02807958
Increase pump speed to make sure that the control rack position reaches Ra.
Illustration 66 g02807959
Full-load Adjustment
Illustration 67 g02807997
Install the cover and adjust full-load stopper bolt
Install cover (3) on governor using bolts and lockwashers (2). Use caution when installing the cover to make sure that the O-ring seal is in the seal groove.
Illustration 68 g02807999
Position the control lever at maximum-speed position.
Adjust full-load stopper bolt (1) to the f"ull-load fuel injection quantity" position. See TMI for the specifications (Point A).
Install cap.Control Lever Angle Measurement
Illustration 69 g02808016
Measuring control lever angle at the "full-speed" and "idling" positions.
Measuring the control lever angle at the "idling" and "full" positions.
If the angle is not as specified by TMI, replace the shifters shim. If the control lever is positioned toward the "full" position, replace the shifters shim with a thicker one. When control lever is toward the "idling" position, replace the shim with a thinner one.Check Starting Delivery
Illustration 70 g02808018
Remove measurement adapter
Remove measurement adapter (1) .
Illustration 71 g02808038
Cap must be installed to check delivery rate
Install cap (2) .
Run pump at speed specified in TMI.
Check delivery rate with specifications listed in TMI.
Stop pump rotation.
Illustration 72 g02808058
Adjusting screw for setting fuel flow
If delivery rate does not meet TMI specifications, remove cap (2), loosen lock nut, and adjust screw (3). Adjusting screw outward decreases fuel flow and inward increases fuel flow.
Install cap (2) and recheck delivery rate. Repeat Steps 2 through 6 until delivery rate is at specified value.Lockwiring Caps of Adjustment Screws
All adjustment stops (screws) that directly affect engine performance should be lockwired after adjustment. Do not readjust any stop without using the test stand can adversely affect the engine and engine performance.