Information injection-pump assembly
ZEXEL
106871-9023
1068719023
HYUNDAI
3310072422
3310072422
Rating:
Service parts 106871-9023 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:
106871-9023
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-9023
1068719023
HYUNDAI
3310072422
3310072422
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
134424-1320
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
9.5
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
118
114.5
121.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
F
Rack position
5.8+-0.5
Pump speed
r/min
450
450
450
Each cylinder's injection qty
mm3/st.
17
15.3
18.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.5)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
118
117
119
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.5)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
124
118.8
129.2
Difference in delivery
mm3/st.
10.4
10.4
10.4
Fixing the lever
*
Injection quantity adjustment_05
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
*
Remarks
(check)
(check)
Injection quantity adjustment_06
Adjusting point
E
Rack position
11.6+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
105
145
Fixing the lever
*
Remarks
Rack limit using stop lever.
Rack limit using stop lever.
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
1.7
1.2
2.2
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
6.5
6
7
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Rack limit using stop lever
(2)Excess fuel setting for starting: SXL
(3)Damper spring setting: DL
----------
SXL=R1+0.2mm DL=4.3-0.2mm
----------
----------
SXL=R1+0.2mm DL=4.3-0.2mm
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=16deg+-5deg b=18deg+-3deg
----------
----------
a=16deg+-5deg b=18deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, stopper bolt setting
(2)Point E setting
----------
aa=4-0.5mm
----------
a=5deg+-6deg b=(34deg)+-6deg
----------
aa=4-0.5mm
----------
a=5deg+-6deg b=(34deg)+-6deg
0000001501 MICRO SWITCH
Switch adjustment
Adjust the bolt so that the lower lever position is obtained when the switch is turned ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325+-25r/min Ra=5.6mm
----------
----------
N1=325+-25r/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:
Lubrication For A Rebuilt Engine
It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine or an engine that has been in storage can cause bearing damage.To prevent the possibility of a "dry start" and bearing damage during the first few seconds of running, use the 1P0540 Flow Checking Tool Group and shop air pressure to pressure lubricate (fill the main oil passage with oil under pressure) all rebuilt engines and all engines that have been in storage.Procedure For Pressure Lubrication
1. Clean the tank of the 1P0540 Flow Checking Tool Group thoroughly, and set the pressure regulator to 240 35 kPa (35 5 psi).
Air pressure should not be more than 345 kPa (50 psi) at any time.
2. Put the correct engine oil into the tank. Use a minimum of 30% of the engine oil capacity. For some engines it will be necessary to fill the tank several times to get the correct amount of oil in the engine.3. Connect the tooling to the main oil passage of the engine.4. Add air pressure to the tank, with the regulator set at 240 35 kPa (35 5 psi). Although the tank has a hand pump, it is difficult to get enough air pressure to do the job with the hand pump. Therefore, use of shop air is recommended.5. Let the engine oil flow into the oil passage under pressure.Fill the crankcase with the correct engine oil. The amount of oil used in the pressure lubrication procedure must be subtracted from the recommended refill capacity in the Operation Maintenance Manual. If the engine is not going to be used for a long time, do the above procedure again before the first start.If shop air is not available, for charging the tank, the hand pump may be used to get the minimum required pressure.
DO NOT use the same 1P0540 Flow Checking Tool Group for both "pressure lubrication application" and for checking fuel flow. Incorrect cleaning is probable if the tool is used for both fuel and lubrication oil. Even a minute amount of dirt in the fuel system can cause fuel nozzle failure.
It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine or an engine that has been in storage can cause bearing damage.To prevent the possibility of a "dry start" and bearing damage during the first few seconds of running, use the 1P0540 Flow Checking Tool Group and shop air pressure to pressure lubricate (fill the main oil passage with oil under pressure) all rebuilt engines and all engines that have been in storage.Procedure For Pressure Lubrication
1. Clean the tank of the 1P0540 Flow Checking Tool Group thoroughly, and set the pressure regulator to 240 35 kPa (35 5 psi).
Air pressure should not be more than 345 kPa (50 psi) at any time.
2. Put the correct engine oil into the tank. Use a minimum of 30% of the engine oil capacity. For some engines it will be necessary to fill the tank several times to get the correct amount of oil in the engine.3. Connect the tooling to the main oil passage of the engine.4. Add air pressure to the tank, with the regulator set at 240 35 kPa (35 5 psi). Although the tank has a hand pump, it is difficult to get enough air pressure to do the job with the hand pump. Therefore, use of shop air is recommended.5. Let the engine oil flow into the oil passage under pressure.Fill the crankcase with the correct engine oil. The amount of oil used in the pressure lubrication procedure must be subtracted from the recommended refill capacity in the Operation Maintenance Manual. If the engine is not going to be used for a long time, do the above procedure again before the first start.If shop air is not available, for charging the tank, the hand pump may be used to get the minimum required pressure.
DO NOT use the same 1P0540 Flow Checking Tool Group for both "pressure lubrication application" and for checking fuel flow. Incorrect cleaning is probable if the tool is used for both fuel and lubrication oil. Even a minute amount of dirt in the fuel system can cause fuel nozzle failure.