Information injection-pump assembly
ZEXEL
106871-7490
1068717490
Rating:
Service parts 106871-7490 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)/21.6(220)
15.
NOZZLE SET
Include in #1:
106871-7490
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-7490
1068717490
Zexel num
Bosch num
Firm num
Name
106871-7490
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
132424-0620
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
1-2-7-3-
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
10
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
129
125.1
132.9
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(10)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
129
128
130
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
131.7
126.3
137.1
Difference in delivery
mm3/st.
10.8
10.8
10.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
160
140
180
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
900
Advance angle
deg.
1
Load
3/4
Remarks
Q=121 (mm3/st) / N=700(r/min)
Q=121 (mm3/st) / N=700(r/min)
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
5
4.5
5.5
Load
4/4
Remarks
Q=155 (mm3/st) / N=700 (r/min), end of advance
Q=155 (mm3/st) / N=700 (r/min), end of advance
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Excess fuel setting for starting: SXL
(2)Damper spring setting: DL
----------
SXL=10.8+-0.1mm DL=4.3-0.2mm
----------
----------
SXL=10.8+-0.1mm DL=4.3-0.2mm
----------
Speed control lever angle
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
----------
aa=1150r/min bb=960r/min
----------
a=21deg+-5deg b=3deg+-5deg
----------
aa=1150r/min bb=960r/min
----------
a=21deg+-5deg b=3deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=28deg+-3deg
----------
----------
a=10deg+-5deg b=28deg+-3deg
Stop lever angle
N:Pump normal
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=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-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:
start by: a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A). The fuel filter does not have to be removed to remove the fuel transfer pump.2. Install timing pin (1) to keep the injection pump camshaft from turning during disassembly and assembly. 3. Install bolt (B) in the threads of sleeve (3). Tighten the bolt until the sleeve can be removed.
Do not hit on the bolt or sleeve. This will cause damage to the unit.
4. Remove four bolts (4) that hold the pump body to the housing.5. Remove body (2) from the housing.6. Remove idler gear (6) from the pump body.7. Remove O-ring seal (5) and the two lip-type seals from the body. 8. Remove drive gear (8) from the shaft.9. Remove key (7) from the shaft.Install Fuel Transfer Pump
1. Install the inner seal in the body with tool (A). The lip of the seal must be toward the pump gears.2. Install the outer seal in the body with tool (B). The lip of the seal must be toward the outside.
Always be careful not to scratch or cause damage to the machined surface of the pump body.
3. Install O-ring seal (2) and idler gear (1) on the body. 4. Install the key and drive gear (3) on the shaft. 5. Install body (4) on the housing.6. Install the bolts that hold the body to the housing. 7. Put sleeve (5) in position on the camshaft. Timing pin (6) must be in position as shown to keep the camshaft from turning during assembly.8. Install the sleeve on the camshaft with tool (C).
Do not hit the sleeve with a hammer to install it. This will put end force on the camshaft and cause damage to the other components in the pump housing.
9. The end clearance of the camshaft must be .023 .018 in. (0.58 0.46 mm) after sleeve (5) is installed.end by: a) install fuel injection pump housing and governor.
Do not hit on the bolt or sleeve. This will cause damage to the unit.
4. Remove four bolts (4) that hold the pump body to the housing.5. Remove body (2) from the housing.6. Remove idler gear (6) from the pump body.7. Remove O-ring seal (5) and the two lip-type seals from the body. 8. Remove drive gear (8) from the shaft.9. Remove key (7) from the shaft.Install Fuel Transfer Pump
1. Install the inner seal in the body with tool (A). The lip of the seal must be toward the pump gears.2. Install the outer seal in the body with tool (B). The lip of the seal must be toward the outside.
Always be careful not to scratch or cause damage to the machined surface of the pump body.
3. Install O-ring seal (2) and idler gear (1) on the body. 4. Install the key and drive gear (3) on the shaft. 5. Install body (4) on the housing.6. Install the bolts that hold the body to the housing. 7. Put sleeve (5) in position on the camshaft. Timing pin (6) must be in position as shown to keep the camshaft from turning during assembly.8. Install the sleeve on the camshaft with tool (C).
Do not hit the sleeve with a hammer to install it. This will put end force on the camshaft and cause damage to the other components in the pump housing.
9. The end clearance of the camshaft must be .023 .018 in. (0.58 0.46 mm) after sleeve (5) is installed.end by: a) install fuel injection pump housing and governor.
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106871-7490
INJECTION-PUMP ASSEMBLY