Information injection-pump assembly
ZEXEL
106871-0920
1068710920
Rating:
Service parts 106871-0920 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97071
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106871-0920
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-0920
1068710920
Zexel num
Bosch num
Firm num
Name
106871-0920
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 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.
129.3
128.3
130.3
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-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_03
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
1000
Advance angle
deg.
1.9
1.4
2.4
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Torque control spring setting
(3)Excess fuel setting for starting: SXL (N = N1)
(4)Damper spring setting
----------
SXL=10.1+-0.1mm N1=400r/min
----------
----------
SXL=10.1+-0.1mm N1=400r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=5deg+-5deg
----------
----------
a=5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=46mm
----------
a=26deg+-3deg b=33deg+-5deg
----------
aa=46mm
----------
a=26deg+-3deg b=33deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Drive side
----------
----------
a=20deg+-5deg b=64deg+-5deg
----------
----------
a=20deg+-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:
Start By:a. remove valve covers 1. Use Tool (A) and disconnect fuel line (1) at each end. Remove the fuel line from the engine. 2. Use Tool (B) and remove retainer (2) from the adapter.3. Remove the fuel injection nozzles with Tool (C) as follows:a. Install the 6V6983 Adapter and the 8T3199 Screw into nozzle assembly (3).b. Install the 8T3198 Tube over the 8T3199 Screw.c. Use the 1B4206 Nut on the 8T3199 Screw to pull the fuel injection nozzle (3).4. Remove compression seal (4) and carbon dam seal (8) from fuel injection nozzle (3).5. Use Tool (D) and remove adapter (6) from the cylinder head.6. Remove gasket (7) and seal (5) from adapter (6). The following steps are for the installation of the fuel injection nozzles and adapters.7. Use Tool (E) to clean the bore in adapter (6). Use an open end wrench or tap driver to turn Tool (E).8. Inspect seal (5) for damage or wear. Replace the seal if necessary.9. Put washer (7) and seal (5) in position on adapter (6).10. Put liquid soap in the bores of the cylinder head and on seals (5) in the adapters.11. Put 5P3931 Anti-Seize Compound on the threads of adapter (6) and install the adapter in the cylinder head assembly.12. Use Tool (D) and tighten the adapter to a torque of 205 14 N m (150 10 lb ft).
Make sure the correct compression seal washer (4) is used when the nozzle assembly is installed in the adapter. Only copper washers are to be used with this adapter.
13. Install compression seal washer (4) and use Tool (F) to install carbon dam seal (8) on the fuel injection nozzle.14. Put fuel injection nozzle (3) in position in the adapter and install retainer (2).15. Use Tool (B) to tighten retainer (2) to a torque of 48 7 N m (35 5 lb ft).16. Install fuel line (1). Tighten the nuts on the fuel line with Tool (A) to a torque of 40 7 N m (30 5 lb ft).End By:a. install valve covers
Make sure the correct compression seal washer (4) is used when the nozzle assembly is installed in the adapter. Only copper washers are to be used with this adapter.
13. Install compression seal washer (4) and use Tool (F) to install carbon dam seal (8) on the fuel injection nozzle.14. Put fuel injection nozzle (3) in position in the adapter and install retainer (2).15. Use Tool (B) to tighten retainer (2) to a torque of 48 7 N m (35 5 lb ft).16. Install fuel line (1). Tighten the nuts on the fuel line with Tool (A) to a torque of 40 7 N m (30 5 lb ft).End By:a. install valve covers
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106871-0920
INJECTION-PUMP ASSEMBLY