Information injection-pump assembly
ZEXEL
106871-0560
1068710560
Rating:
Cross reference number
ZEXEL
106871-0560
1068710560
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 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
9.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
106.5
105.5
107.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.6+-0.5
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
105.6
103.6
107.6
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
F
Rack position
6+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
11.5
9.5
13.5
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)Lever ratio: RT
(2)Target shim dimension: TH
(3)Rack limit using the stop lever: R1
(4)Excess fuel setting for starting: SXL
(5)Damper spring setting: DL
----------
RT=1 TH=2.2mm R1=13.8+0.2mm SXL=10.1+-0.1mm DL=5.6-0.2mm
----------
----------
RT=1 TH=2.2mm R1=13.8+0.2mm SXL=10.1+-0.1mm DL=5.6-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=0deg+-5deg
----------
----------
a=0deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=24.5deg+-5deg b=25.5deg+-3deg
----------
----------
a=24.5deg+-5deg b=25.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
----------
aa=13.8+0.2mm
----------
a=10.5deg+-5deg b=36deg+-5deg
----------
aa=13.8+0.2mm
----------
a=10.5deg+-5deg b=36deg+-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:
Warning Operation
Two flashing warning lamps and an alarm inform the operator that: * An ether cylinder is empty.* Both ether cylinders are empty.* A noncritical fault is present.* A critical fault is present.The warning lamps and alarm can be tested by placing the ether system switch in the Test/Disable position. The warning alarm will turn ON for two seconds and the warning lamps will remain ON continuously until the switch is returned to the Auto position. If a solenoid valve is shorted to +BAT, the alarm sounds whenever the key switch is in the RUN or START position. The alarm beeps at the rate of approximately 1.3 seconds ON and 2.0 seconds OFF. The engine could be damaged if ether was injected before the engine is cranked.An Ether Cylinder Is Empty
One of the two warning lamps inform the operator when an ether cylinder is empty. The lamp flashes at the rate of 1.5 Hz (flashes per second) with equal ON and OFF times. The lamps and ether solenoid assemblies are correspondingly marked 1 and 2. When empty ether cylinder warning lamp 1 is flashing, ether cylinder 1 needs replaced. When empty ether cylinder warning lamp 2 is flashing, ether cylinder 2 needs replaced. (On 3516 engines, both ether cylinders of the set need replaced.) The lamps stop flashing when the reset switch is activated during ether cylinder replacement. The empty ether cylinder warning lamp will also flash if there is no ether cylinder installed.Both Ether Cylinders Are Empty
When both ether cylinders are empty (on 3516 engines, both ether cylinder sets), both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash at the same time, at the rate of 1.5 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF.A Noncritical Fault Is Present
When a noncritical fault is present, both empty ether cylinder warning lamps are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The system continues to operate during a noncritical fault.A Critical Fault Is Present
When a critical fault is present. both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF. If possible, ether injections are disabled during a critical fault.Diagnostic Operation
Ether Injection Control DiagnosticsThe ether injection control has diagnostic capabilities to assist in troubleshooting. The control detects and records faults that occur to the system. During a critical fault, if possible, the control disables ether injection. During a noncritical fault, the control takes alternate action so that the system continues to function.The diagnostic display, on the ether injection control, displays a code which represents the fault that
Two flashing warning lamps and an alarm inform the operator that: * An ether cylinder is empty.* Both ether cylinders are empty.* A noncritical fault is present.* A critical fault is present.The warning lamps and alarm can be tested by placing the ether system switch in the Test/Disable position. The warning alarm will turn ON for two seconds and the warning lamps will remain ON continuously until the switch is returned to the Auto position. If a solenoid valve is shorted to +BAT, the alarm sounds whenever the key switch is in the RUN or START position. The alarm beeps at the rate of approximately 1.3 seconds ON and 2.0 seconds OFF. The engine could be damaged if ether was injected before the engine is cranked.An Ether Cylinder Is Empty
One of the two warning lamps inform the operator when an ether cylinder is empty. The lamp flashes at the rate of 1.5 Hz (flashes per second) with equal ON and OFF times. The lamps and ether solenoid assemblies are correspondingly marked 1 and 2. When empty ether cylinder warning lamp 1 is flashing, ether cylinder 1 needs replaced. When empty ether cylinder warning lamp 2 is flashing, ether cylinder 2 needs replaced. (On 3516 engines, both ether cylinders of the set need replaced.) The lamps stop flashing when the reset switch is activated during ether cylinder replacement. The empty ether cylinder warning lamp will also flash if there is no ether cylinder installed.Both Ether Cylinders Are Empty
When both ether cylinders are empty (on 3516 engines, both ether cylinder sets), both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash at the same time, at the rate of 1.5 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF.A Noncritical Fault Is Present
When a noncritical fault is present, both empty ether cylinder warning lamps are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The system continues to operate during a noncritical fault.A Critical Fault Is Present
When a critical fault is present. both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF. If possible, ether injections are disabled during a critical fault.Diagnostic Operation
Ether Injection Control DiagnosticsThe ether injection control has diagnostic capabilities to assist in troubleshooting. The control detects and records faults that occur to the system. During a critical fault, if possible, the control disables ether injection. During a noncritical fault, the control takes alternate action so that the system continues to function.The diagnostic display, on the ether injection control, displays a code which represents the fault that