Information injection-pump assembly
ZEXEL
106871-9310
1068719310
Rating:
Cross reference number
ZEXEL
106871-9310
1068719310
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
10.2
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
132.5
128.5
136.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.4+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
19
16.1
21.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.2)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
132.5
131.5
133.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R2(R1+0.
75)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
144.5
140.5
148.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
115
195
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
(N1+50)-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N1(800)
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
(1100)
Advance angle
deg.
4.5
4
5
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)Excess fuel setting for starting: SXL
(5)Damper spring setting
----------
RT=1 TH=3.1mm SXL=(R2+0.2)+0.2mm
----------
----------
RT=1 TH=3.1mm SXL=(R2+0.2)+0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=(20deg)+-5deg
----------
----------
a=(20deg)+-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
S:Stop the pump.
(1)Rack position = [(non-injection rack at N = aa)-bb]-cc
(2)Stopper bolt setting
(3)Free (at shipping)
(4)Drive side
(5)Actual measurement
----------
aa=1320r/min bb=0.3mm cc=0.5mm
----------
a=10.5deg+-5deg
----------
aa=1320r/min bb=0.3mm cc=0.5mm
----------
a=10.5deg+-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=325r/min Ra=4.9+-0.1mm
----------
----------
N1=325r/min Ra=4.9+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=13deg
----------
a=(40deg)
----------
aa=13deg
----------
a=(40deg)
Information:
Recommended Procedure With Chassis Dynamometer
Possible Causes/Corrections
Minor Operating Faults/To help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the PRIMARY ENGINE CHECKS section. Fuel Ratio Control Out of Adjustment or Bad/Follow the procedure in the Testing and Adjusting section of this Service Manual. Check Engine Performance/Do a Power Analysis report (PAR), Level II, to check engine performance. See Special Instruction, Form No. SEHS8025 and SEHS7886 for the tooling and procedures to use. Be sure to make a record of the temperatures for inlet air, fuel (at filter base), lubricating oil and coolant. Fuel Settings Not Correct/If the Power Analysis Report indicates a problem, the governor fuel settings should be verified. See the Testing and Adjusting section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see OWNER/OPERATOR INPUT section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic. Bad Fuel Nozzle(s)/Remove the fuel nozzles and test as in the Testing and Adjusting section of this Service Manual.Recommended Procedure Without Chassis Dynamometer
Possible Causes/Corrections
Minor Operating Faults/To help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the PRIMARY ENGINE CHECKS section. Fuel Ratio Control Out of Adjustment or Bad/Follow the procedure in the Testing and Adjusting section of this Service Manual. Fuel Injection Timing Not Correct/Follow the procedures in the Testing and Adjusting section of this Service Manual. Check Engine Performance/Install the tooling and follow the procedure given in the ROAD TEST section. Fuel Settings Not Correct/If the Road Test indicates a problem, the governor fuel settings should be verified. See the Testing and Adjusting section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see OWNER/OPERATOR INPUT section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic. Any Further Diagnosis Must Be Done On A Chassis Dynamometer/If the fuel settings are correct and the above procedures have been followed without finding the problem a Power Analysis Report (PAR), Level II, must be done on the engine. See Special Instruction, Form Nos. SEHS8025 and SEHS7886 for the correct tools and procedures to use.
Possible Causes/Corrections
Minor Operating Faults/To help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the PRIMARY ENGINE CHECKS section. Fuel Ratio Control Out of Adjustment or Bad/Follow the procedure in the Testing and Adjusting section of this Service Manual. Check Engine Performance/Do a Power Analysis report (PAR), Level II, to check engine performance. See Special Instruction, Form No. SEHS8025 and SEHS7886 for the tooling and procedures to use. Be sure to make a record of the temperatures for inlet air, fuel (at filter base), lubricating oil and coolant. Fuel Settings Not Correct/If the Power Analysis Report indicates a problem, the governor fuel settings should be verified. See the Testing and Adjusting section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see OWNER/OPERATOR INPUT section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic. Bad Fuel Nozzle(s)/Remove the fuel nozzles and test as in the Testing and Adjusting section of this Service Manual.Recommended Procedure Without Chassis Dynamometer
Possible Causes/Corrections
Minor Operating Faults/To help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the PRIMARY ENGINE CHECKS section. Fuel Ratio Control Out of Adjustment or Bad/Follow the procedure in the Testing and Adjusting section of this Service Manual. Fuel Injection Timing Not Correct/Follow the procedures in the Testing and Adjusting section of this Service Manual. Check Engine Performance/Install the tooling and follow the procedure given in the ROAD TEST section. Fuel Settings Not Correct/If the Road Test indicates a problem, the governor fuel settings should be verified. See the Testing and Adjusting section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see OWNER/OPERATOR INPUT section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic. Any Further Diagnosis Must Be Done On A Chassis Dynamometer/If the fuel settings are correct and the above procedures have been followed without finding the problem a Power Analysis Report (PAR), Level II, must be done on the engine. See Special Instruction, Form Nos. SEHS8025 and SEHS7886 for the correct tools and procedures to use.