Information injection-pump assembly
ZEXEL
106681-4330
1066814330
YANMAR
12661351010
12661351010
Rating:
Service parts 106681-4330 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:
106681-4330
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106681-4330
1066814330
YANMAR
12661351010
12661351010
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131424-7120
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
1-4-2-6-
3-5
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
16.5
Pump speed
r/min
1100
1100
1100
Each cylinder's injection qty
mm3/st.
456
442.3
469.7
Basic
*
Fixing the lever
*
Boost pressure
kPa
120
120
Boost pressure
mmHg
900
900
Injection quantity adjustment_02
Adjusting point
B
Rack position
7+-0.5
Pump speed
r/min
200
200
200
Each cylinder's injection qty
mm3/st.
30
27
33
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
455
445
465
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
R1-3.2
Boost pressure
kPa
40
37.3
42.7
Boost pressure
mmHg
300
280
320
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(16.5)
Boost pressure
kPa
107
100.3
113.7
Boost pressure
mmHg
800
750
850
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1025
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
K=9 BCL=3.2+-0.1mm
----------
----------
K=9 BCL=3.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=12deg+-5deg b=36deg+-5deg
----------
----------
a=12deg+-5deg b=36deg+-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=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=(73deg)
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:
1. Remove two bolts (1) from the top of the water pump. Loosen two bolts (2) in the water pump.
TYPICAL EXAMPLE2. Remove oil supply line (3) from the turbocharger. Remove oil return line (4) from the turbocharger.
TYPICAL EXAMPLE3. Remove the bolts (5) that hold the cylinder head to the cylinder block.
TYPICAL EXAMPLE4. Fasten a hoist to the cylinder head assembly (6). Remove the cylinder head assembly from the block. Weight of the assembly is 290 lb. (131 kg). Remove O-ring seal from hollow dowel. Remove cylinder head gasket (7) and water ferrules.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
Always install a new gasket between spacer plate and cylinder block before cylinder head is installed. See REMOVE SPACER PLATE.Install Cylinder Head
TYPICAL EXAMPLE1. Thoroughly clean the spacer plate and bottom surface of the cylinder head. Install a new head gasket (2), water ferrules (1) and O-ring seal (3) on the hollow dowel. Be sure a new gasket has been installed between spacer plate and cylinder block. See INSTALL SPACER PLATE.2. Fasten a hoist and install the cylinder head assembly (4) on the cylinder block. 3. Install the push rods and put the rocker shaft in position on the cylinder head. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head and rocker shaft bolts. Install the bolts and washers and tighten the bolts as follows: 1. Tighten all bolts in number sequence to a torque of 115 lb. ft. (155 N m).2. Again tighten all bolts in number sequence to a torque of 185 13 lb. ft. (250 17 N m).3. Again tighten all bolts in number sequence (hand torque only) to a torque of 185 13 lb. ft. (250 17 N m).4. Tighten all bolts in letter sequence to a torque of 32 5 lb. ft. (43 7 N m).4. Make adjustment of valves to have a clearance of .015 in. (0.38 mm) for intake and .025 in. (0.64 mm) for exhaust.
TYPICAL EXAMPLE5. Install oil return line (6) on the turbocharger.6. Install oil supply line (5) on the turbocharger. 7. Tighten the two bolts (8) in the water pump.8. Install the two bolts (7) that hold the water pump to the cylinder head.end by: a) install fuel injection lines
TYPICAL EXAMPLE2. Remove oil supply line (3) from the turbocharger. Remove oil return line (4) from the turbocharger.
TYPICAL EXAMPLE3. Remove the bolts (5) that hold the cylinder head to the cylinder block.
TYPICAL EXAMPLE4. Fasten a hoist to the cylinder head assembly (6). Remove the cylinder head assembly from the block. Weight of the assembly is 290 lb. (131 kg). Remove O-ring seal from hollow dowel. Remove cylinder head gasket (7) and water ferrules.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
Always install a new gasket between spacer plate and cylinder block before cylinder head is installed. See REMOVE SPACER PLATE.Install Cylinder Head
TYPICAL EXAMPLE1. Thoroughly clean the spacer plate and bottom surface of the cylinder head. Install a new head gasket (2), water ferrules (1) and O-ring seal (3) on the hollow dowel. Be sure a new gasket has been installed between spacer plate and cylinder block. See INSTALL SPACER PLATE.2. Fasten a hoist and install the cylinder head assembly (4) on the cylinder block. 3. Install the push rods and put the rocker shaft in position on the cylinder head. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head and rocker shaft bolts. Install the bolts and washers and tighten the bolts as follows: 1. Tighten all bolts in number sequence to a torque of 115 lb. ft. (155 N m).2. Again tighten all bolts in number sequence to a torque of 185 13 lb. ft. (250 17 N m).3. Again tighten all bolts in number sequence (hand torque only) to a torque of 185 13 lb. ft. (250 17 N m).4. Tighten all bolts in letter sequence to a torque of 32 5 lb. ft. (43 7 N m).4. Make adjustment of valves to have a clearance of .015 in. (0.38 mm) for intake and .025 in. (0.64 mm) for exhaust.
TYPICAL EXAMPLE5. Install oil return line (6) on the turbocharger.6. Install oil supply line (5) on the turbocharger. 7. Tighten the two bolts (8) in the water pump.8. Install the two bolts (7) that hold the water pump to the cylinder head.end by: a) install fuel injection lines