Information injection-pump assembly
ZEXEL
106675-4660
1066754660
Rating:
Service parts 106675-4660 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
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:
106675-4660
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106675-4660
1066754660
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
131424-1520
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
3.9
3.85
3.95
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
12
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
169.5
167.5
171.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
133
133
Boost pressure
mmHg
1000
1000
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.6+-0.5
Pump speed
r/min
315
315
315
Average injection quantity
mm3/st.
10
8.7
11.3
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-2.2
Boost pressure
kPa
20
14.7
25.3
Boost pressure
mmHg
150
110
190
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(12)
Boost pressure
kPa
120
120
120
Boost pressure
mmHg
900
900
900
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)Set idle sub-spring
(4)Main spring setting
(5)Boost compensator stroke
----------
K=17
----------
----------
K=17
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=15deg+-5deg b=28deg+-5deg
----------
----------
a=15deg+-5deg b=28deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Pump speed aa and rack position bb (to be sealed at delivery)
(3)Use the hole above R = cc
----------
aa=0r/min bb=1-0.5mm cc=30mm
----------
a=32deg+-5deg b=70deg+-5deg
----------
aa=0r/min bb=1-0.5mm cc=30mm
----------
a=32deg+-5deg b=70deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Introduction
The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .Note: The 162-2501 Hose As replaces 107-7942 Tube As .Installation Procedure of the Hose Assembly
Illustration 1 g01230674
Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.Note: Step 2 is only for 3408E engines.
Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.
Illustration 2 g01230678
Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.
Loosen elbow (4) and jam nut (5) .
Hand tighten the nut on the hose (5) to the elbow (4) .
Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 15 N m (90 11 lb ft).
Hold the elbow (4) in position and torque the jam nut to 145 15 N m (105 11 lb ft).
Support the elbow (4). Tighten the nut (5) on the hose to 125 15 N m (90 11 lb ft).
Illustration 3 g01230687
Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.
Illustration 4 g01230689
Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.
Illustration 5 g01230690
The hose must be realigned if any of the following conditions exist:
Not enough clearance against the fuel transfer pump
Not enough clearance against the support bracket
Loosen the end of the hose (12) .
Loosen the elbow and the jam nut (11). Note: Do not remove the hose.
Reposition the hose in order to acquire the desired clearance.
Hold the end of the hose (12). Tighten the jam nut (11) .Tighten the jam nut to the following torque. ... 143 15 N m (105 11 lb ft)Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.
Tighten the end of the hose (12) .Tighten the end of the hose to the following torque. ... 125 15 N m (92 11 lb ft)Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.Installation of the Protective Sleeve Over the New Hose Assembly
Illustration 6 g01106118
Top viewInstallation of a protective sleeve for the hoses of the
The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .Note: The 162-2501 Hose As replaces 107-7942 Tube As .Installation Procedure of the Hose Assembly
Illustration 1 g01230674
Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.Note: Step 2 is only for 3408E engines.
Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.
Illustration 2 g01230678
Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.
Loosen elbow (4) and jam nut (5) .
Hand tighten the nut on the hose (5) to the elbow (4) .
Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 15 N m (90 11 lb ft).
Hold the elbow (4) in position and torque the jam nut to 145 15 N m (105 11 lb ft).
Support the elbow (4). Tighten the nut (5) on the hose to 125 15 N m (90 11 lb ft).
Illustration 3 g01230687
Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.
Illustration 4 g01230689
Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.
Illustration 5 g01230690
The hose must be realigned if any of the following conditions exist:
Not enough clearance against the fuel transfer pump
Not enough clearance against the support bracket
Loosen the end of the hose (12) .
Loosen the elbow and the jam nut (11). Note: Do not remove the hose.
Reposition the hose in order to acquire the desired clearance.
Hold the end of the hose (12). Tighten the jam nut (11) .Tighten the jam nut to the following torque. ... 143 15 N m (105 11 lb ft)Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.
Tighten the end of the hose (12) .Tighten the end of the hose to the following torque. ... 125 15 N m (92 11 lb ft)Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.Installation of the Protective Sleeve Over the New Hose Assembly
Illustration 6 g01106118
Top viewInstallation of a protective sleeve for the hoses of the