Information injection-pump assembly
ZEXEL
106871-2820
1068712820
Rating:
Service parts 106871-2820 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME066499
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106871-2820
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-2820
1068712820
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
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 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 1-3 deg. 135 134.5 135.5
Cal 1-3 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 1-5 deg. 225 224.5 225.5
Cal 1-5 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
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
156
151
161
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.1+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
20
17
23
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
156
155
157
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11.4)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
164
157
171
Difference in delivery
mm3/st.
14
14
14
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
(9.2)
Boost pressure
kPa
4
4
4
Boost pressure
mmHg
30
30
30
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1(11.4)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
(900+-50
)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Boost compensator cancel stroke: BSL
(2)Damper spring setting: DL
(3)Boost compensator stroke: BCL
----------
BSL=2.6mm DL=4.3-0.2mm BCL=2.2+-0.1mm
----------
----------
BSL=2.6mm DL=4.3-0.2mm BCL=2.2+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=18deg+-5deg
----------
----------
a=18deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=29.5deg+-3deg
----------
----------
a=10deg+-5deg b=29.5deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at shipping)
----------
aa=4-0.5mm bb=14.6mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)
----------
aa=4-0.5mm bb=14.6mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325+-5r/min Ra=5.6mm
----------
----------
N1=325+-5r/min Ra=5.6mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
Close the gauge protector valve ( 0 to 40,000 kPa (0 to 5,800 psi) gauge).
Visually inspect the pattern of the fuel nozzle for a uniform spray.Note: For this test, each full stroke of the pump should be performed in less than one second.
Rapidly increase the pressure on the fuel nozzle until fluid sprays from the tip of the fuel nozzle.
Test fluid should spray from the tip of the nozzle in a pattern that is uniform. Refer to Illustration 2.
Check the individual spray orifices for partial plugging.
Use a moderate pump stroke to open the valve of the fuel nozzle.
During the pump stroke, view the individual spray orifices for partial plugging.The test fluid should spray uniformly from all the orifices.If an orifice is plugged or the pattern is distorted, clean the fuel nozzle orifices and repeat this test. Refer to Special Instruction, SEHS8627, "Use of 8S-2245 Nozzle Cleaning Tool Group" for instructions on tool usage and cleaning procedures.Test the Fuel Nozzle for Seal Leakage
Note: Testing for seal leakage is not a requirement for the 104-9450 Fuel Nozzle, 104-9452 Fuel Nozzle, 104-9453 Fuel Nozzle, or the 104-9454 Fuel Nozzle. Do not perform this test on these fuel nozzles.
Illustration 3 g00453789
Typical example of a 7000 Series fuel nozzle
Remove the cloth from the top of the nozzle.
Prior to performing this test, install a new seal washer on purging screw (A) and reinstall the purging screw into the fuel nozzle.
Illustration 4 g00453809
Tighten purging screw (D) or purging screw (E) to a torque of 2.2 0.8 N m (20 7 lb in). Note: Use a 6V-4980 Torque Screwdriver Tool Group to torque the purging screw.
Apply a test pressure of 13,800 kPa (2,000 psi) to the fuel nozzle.Note: Due to the large amount of test fluid that is delivered to the fuel nozzle, hydraulic lock may prevent the nozzle from opening during this test. If a hydraulic lock occurs, slowly loosen the adapter fitting to relieve the pressure on the fuel nozzle valve assembly.If there is leakage at the purging screw, install a new 8C-3234 Screw and a 114-3364 Washer as replacement parts. Retest the fuel nozzle for leaks.Do not use the nozzle if there is leakage that cannot be repaired at purging screw (A), upper seal joint (B), or lower seal joint (C).Returning Fuel Nozzles to Service
Illustration 5 g00453817Prior to returning fuel nozzles to service, install a new seal washer (3) and install a new carbon dam (4) on the fuel nozzle (1).Use 6V-4979 Carbon Seal Installation Tool (2) to install a new carbon dam (4).Table 5 contains part numbers for the replacement of the fuel nozzle seal washers.
Table 5
Seal Washers
Fuel Nozzle Washer (Color) Washer Thickness
8N-7004 4W-3914 (Gray) 1.27 mm (0.050 inch)
4W-7012
4W-7013
4W-7014
4W-7015 4W-6060 (Blue) 3.18 mm (0.125 inch)
4W-7018
4W-7019
4W-7020
4W-7021
4W-7022
7W-7045
100-7552
100-7562
100-7563
104-3377
167-7489
170-5181
170-5183 7W-4482 (Green) 3.18 mm (0.125 inch)
133-3896 7W-4483 (Red) 2.54 mm (0.100 inch)
4W-7011
4W-7016
7W-7024 7W-4485 (Copper) 1.27 mm (0.050 inch)
8N-7003
7W-7038
8N-7005
100-7559
100-7561
100-7564
104-9450
104-9452
104-9453
104-9454
131-3190
154-3198
170-5187 7W-4486 (Violet) 1.84 mm (0.072 inch)
4W-7017
7W-7026
7W-7030
7W-7031
7W-7032
7W-7033
7W-7035
7W-7037
7W-7040
7W-7041
7W-7042
7W-7043
7W-7044
8N-7007
100-7550
100-7551
100-7556
100-7557
100-7558
100-7560
100-7565
100-7567
100-7600
121-4353
127-9792
127-9793
129-1351
130-1804
130-1806
130-5187
130-5190
131-0811
131-0812
131-1242
131-1243
131-7937
134-0944
171-4093 7W-4487 (Black) 1.27 mm (0.050 inch)
7W-7023