Information injection-pump assembly
ZEXEL
106871-0860
1068710860
Rating:
Service parts 106871-0860 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97073
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106871-0860
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-0860
1068710860
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
9.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
115.7
114.7
116.7
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
120
116
124
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.7+-0.5
Pump speed
r/min
235
235
235
Average injection quantity
mm3/st.
10.4
8.4
12.4
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
155
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
875
Advance angle
deg.
0.5
Load
3/4
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
1.7
1.2
2.2
Load
4/4
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
5
4.5
5.5
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Excess fuel setting for starting: SXL
(3)Damper spring setting
(4)Variable speed specification: idling adjustment
(5)(Fix in the full position at delivery.)
(6)Main spring setting
----------
SXL=10.3+-0.1mm
----------
----------
SXL=10.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)(Pump speed = aa)
(2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=(11deg)+-5deg b=5deg+-5deg
----------
aa=290r/min
----------
a=(11deg)+-5deg b=5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=23.5deg+-3deg
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=23.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Drive side
----------
----------
a=12deg+-5deg b=64deg+-5deg
----------
----------
a=12deg+-5deg b=64deg+-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:
Use tool (E) in order to cut off the part of rivet (1) that has been peened. Remove rivet (1) from fuel injection control linkage (4) .
Illustration 13 g00702186
The 180-7951 Bushing Assembly Kit (F) Rack Control Shaft (G) Governor Link (4) Fuel Injection Control Linkage (7) 180-7952 Lever Bushing (8) 8L-5832 Hex Nut (9) 9X-8907 Hexagon Button Screw
Use the 180-7951 Bushing Assembly Kit in order to modify the linkage. Insert 9X-8907 Hexagon Button Screw (9) from the 180-7951 Bushing Assembly Kit into fuel injection control linkage (4). Refer to Illustration 13.
Apply 169-5464 Quick Cure Primer apply on the threads of 9X-8907 Hexagon Button Screw (9) and 8L-5832 Hex Nut (8). Allow the primer to dry. The Quick Cure Primer counteracts the effects of the Volatile Corrosion Inhibitor (VCI) paper that was used to package the parts.
Assemble 180-7952 Lever Bushing (7) on 9X-8907 Hexagon Button Screw (9). Refer to Illustration 13.
Apply the 154-9731 Thread Lock Compound on the threads of 9X-8907 Hexagon Button Screw (9) and 8L-5832 Hex Nut (8) .
Illustration 14 g00655322
Place 8L-5832 Hex Nut (8) on 9X-8907 Hexagon Button Screw (9). Tighten 8L-5832 Hex Nut (8) until hex nut (8) is snug. Tighten 8L-5832 Hex Nut (8) for an additional 180 degrees.
Do not let metal chips or pieces of the rivet fall into the engine.
Illustration 15 g00655325
Clean the fuel injection control linkage and clean the surfaces of the cylinder head that are adjacent to the fuel injection control linkage with shop solvent. Remove the towels and remove all debris very carefully.
Install the 180-7956 Clamp Assembly Kit . Refer to the "Installation Of The 180-7956 Clamp Assembly Kit " section of this publication.Installation Of The 180-7956 Clamp Assembly Kit
Note: The 180-7956 Clamp Assembly Kit is used for the former control linkages only.Note: If the 180-7956 Clamp Assembly Kit is installed, refer to ""Modification of the 128-9640 Injector Synchronization Fixture "".The 180-7956 Clamp Assembly Kit may be installed on the fuel injection control linkage. The 180-7956 Clamp Assembly Kit will increase the strength of the joint.
Illustration 16 g00655326
Install 183-9390 Spacer (10) on fuel injection control linkage (4). Refer to Illustration 16.
Apply 169-5464 Quick Cure Primer to the threaded hole in the 180-7954 Clamp (11). Apply 169-5464 Quick Cure Primer to the threads of screw (13). Allow the primer to dry. The Quick Cure Primer counteracts the effects of the Volatile Corrosion Inhibitor (VCI) paper that was used to package the parts.
Apply 154-9731 Thread Lock Compound to the threaded hole in the 180-7954 Clamp (11). Apply 154-9731 Thread Lock Compound to the threads of screw (13) of clamp assembly. Loosely assemble 180-7954 Clamp (11) and 180-7987 Clamp (12) on fuel injection control linkage (4). Refer to Illustration 16. Be sure that the rivet head or bushing (14) is fully engaged into the counterbore of the