Information injection-pump assembly
ZEXEL
106871-0301
1068710301
Rating:
Service parts 106871-0301 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1660097019
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Include in #1:
106871-0301
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-0301
1068710301
Zexel num
Bosch num
Firm num
Name
106871-0301
INJECTION-PUMP ASSEMBLY
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
132424-0620
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
1-8-7-5-
4-3-6-2
Pre-stroke
mm
3.65
3.6
3.7
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5
Cal 1-8 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5
Cal 1-5 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5
Cal 1-3 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5
Cyl.1-2 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
10
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
105.2
104.2
106.2
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.3+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
12.9
10.9
14.9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Timer adjustment
Pump speed
r/min
800--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
1.4
0.9
1.9
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Damper spring setting: DL
(2)Rack limit using stop lever (at N = N1 or less).
(3)Excess fuel setting for starting
(4)At pump speed N2
(5)Variable speed specification: idling adjustment
(6)Main spring setting
(7)Set idle sub-spring
----------
DL=6.3-0.2mm N1=100r/min N2=1100r/min
----------
----------
DL=6.3-0.2mm N1=100r/min N2=1100r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(12deg)+-5deg b=(24deg)+-5deg
----------
----------
a=(12deg)+-5deg b=(24deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=24.5deg+-5deg b=31deg+-3deg
----------
----------
a=24.5deg+-5deg b=31deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Use the hole at R = bb
----------
aa=11+0.2mm bb=32mm
----------
a=28.5deg+-5deg b=3deg+-5deg
----------
aa=11+0.2mm bb=32mm
----------
a=28.5deg+-5deg b=3deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder.
(3)-
(4)-
----------
----------
a=(90deg)
----------
----------
a=(90deg)
Information:
(1) Thickness of spacer plate ... 9.970 0.025 mm (.3925 .0010 in) Thickness of spacer plate gasket ... 0.208 0.025 mm (.0082 .0010 in) For height of liner over top of spacer plate make reference to Cylinder Liner Projection.(2) Camshaft bearing bore (installed) ... 58.80 0.06 mm (2.315 .002 in) Bore in block for camshaft bearings ... 65.100 0.025 mm (2.5630 .0010 in)(3) Bore in block for main bearings (standard size) ... 96.926 0.013 mm (3.8160 .0005 in) Bore in block for main bearings 0.51 mm (.020 in) oversize ... 97.436 0.013 mm (3.8361 .0005 in)(4) Dimension from center of main bearing bore to top of cylinder block (new) ... 383.515 0.165 mm (15.099 .0064 in)(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 153.99 0.10 mm (6.063 .004 in)(6) Torque for bolts holding bearing caps for main bearings: a. Put 2P2506 Thread Lubricant on threads and washer face.b. Tighten all bolts to ... 41 4 N m (30 3 lb ft)c. Put a mark on each bolt and cap.d. Tighten all bolts from mark ... 90 5° Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block.(7) Clearance between main bearing cap and cylinder block ... 0.033 mm (.0013 in) tight to 0.043 mm (.0017 in) loose Main bearing cap width ... 165.095 0.020 mm (6.4998 .0008 in)Width of cylinder block for main bearing cap ... 165.100 0.018 mm (6.5000 .0007 in) (8) Bore in bearing for balancer shaft (installed) ... 53.050 0.061 mm (2.0886 .0024 in) Bore in block for bearings ... 57.851 .025 mm (2.2776 .0010 in)Depth to install bearings at both ends of block ... 0.8
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106871-0301
INJECTION-PUMP ASSEMBLY