Information injection-pump assembly
ZEXEL
106871-0890
1068710890
Rating:
Service parts 106871-0890 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97068
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106871-0890
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-0890
1068710890
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
10.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
127.7
126.7
128.7
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.7+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
11.1
9.1
13.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
187
187
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
500--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
450
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
3.5
3
4
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)Tolerance for racks not indicated: +-0.05mm.
(4)Variable speed specification: idling adjustment
(5)Fix the lever at the full-load position at delivery.
(6)Excess fuel setting for starting: SXL
(7)Damper spring setting
(8)Main spring setting
----------
RT=1 TH=2.2mm SXL=10.2+-0.1mm
----------
----------
RT=1 TH=2.2mm SXL=10.2+-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=11.5deg+-5deg b=5deg+-5deg
----------
aa=290r/min
----------
a=11.5deg+-5deg b=5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=26.5deg+-3deg
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=26.5deg+-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:
Typical Example1. Remove bolts (1) and cover (2). Remove bolts (3) and cover (4).
Typical Example2. Remove bolts (5) and adapter (6). Be sure that gear stays in place. Remove bolts (7) and cover (8). Keep gear in place.
Typical Example3. Remove gears (9) and crankshaft gear (10). Remove bolts (11) and idler gear (12) with retainer. Remove bolts (13) and idler gear (14) with retainer.
Typical Example4. Secure strap and a hoist to housing (15). Remove hose assembly (16) and small bolts (17) and large bolts (18). 5. Remove bolts (19) that connect housing to oil pan (20). Remove housing from cylinder block. The weight of housing is approximately 105 kg (230 lb). 6. Check O-ring seal (21) and bearing (22) on adapter and replace if necessary. 7. Check bearing (23) and O-ring seal (24) on cover and replace if necessary. 8. Remove retainer (25) from gear (9) and check bearings (26) and replace if necessary. The following steps are for the installation of the flywheel housing.9. Thoroughly clean the contact surfaces of the cylinder block and flywheel housing. Install a new gasket between the flywheel housing and the cylinder clock.10. Secure strap and a hoist to the flywheel housing, put flywheel housing in position on the cylinder block. 11. Install the bolts that hold the flywheel housing to the cylinder block. Tighten bolts 1 thru 22 in number sequence to a torque of 40 10 N m (30 7 lb ft). Tighten bolts 1 thru 9 in number sequence again to a torque of 135 20 N m (100 15 lb ft). Tighten bolts 10 thru 22 in number sequence again to a torque of 55 10 N m (40 7 lb ft).12. Install bolts that connect housing to oil pan.13. Cut flywheel housing gasket off even with the cylinder block surface. Remove excess sealant.End By:a. install crankshaft rear seal and wear sleeveb. install starting motor