Information injection-pump assembly
ZEXEL
106876-2040
1068762040

Rating:
Cross reference number
ZEXEL
106876-2040
1068762040
Zexel num
Bosch num
Firm num
Name
106876-2040
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
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
A
Rack position
11.3
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
161
158
164
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
15.5
12.9
18.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-1.3
Boost pressure
kPa
21.3
20
22.6
Boost pressure
mmHg
160
150
170
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11.3)
Boost pressure
kPa
48
41.3
54.7
Boost pressure
mmHg
360
310
410
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
1100
Advance angle
deg.
0.5
0
1
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
1
1
1
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Torque spring does not operate.
(3)Excess fuel lever setting: EXL (at boost pressure 0)
(4)Main spring setting
(5)Set idle sub-spring
(6)Boost compensator stroke: BCL
(7)At delivery
----------
K=13 EXL=13++mm BCL=1.3+-0.1mm
----------
----------
K=13 EXL=13++mm BCL=1.3+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
(2)At delivery
----------
----------
a=(12deg)+-5deg b=(28deg)+-5deg c=(2deg)
----------
----------
a=(12deg)+-5deg b=(28deg)+-5deg c=(2deg)
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=19deg+-5deg b=46deg+-5deg
----------
----------
a=19deg+-5deg b=46deg+-5deg
0000001101

N:Normal
B:When boosted
(1)Rack position = at least aa (speed = bb; at boost pressure 0)
----------
aa=13mm bb=0r/min
----------
a=(10deg) b=(15deg)
----------
aa=13mm bb=0r/min
----------
a=(10deg) b=(15deg)
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=14deg
----------
a=(40deg)
----------
aa=14deg
----------
a=(40deg)
Information:
Step 8. Check Signal Voltage At ECMA. Install the 40-Pin Breakout 'T' at the ECM Connector (J4/P4).B. Measure the voltage between Fuel Pressure, Pin 39 and Sensor Return Analog, Pin 35. The signal voltage should correspond to the observed fuel pressure reading shown in Table A. OK: The Fuel Pressure Signal is reaching the ECM. If Step 3 found that the ECM is not reading fuel pressure correctly, then the ECM is defective. Replace the ECM. Stop. NOT OK: The signal was good at the sensor but did not reach the ECM. Repair the wiring harness between Fuel Pressure Sensor and the ECM. Stop.P227: Retarder Enable Signal Test
The "Retarder Enable" signal is provided by the ECM to indicate that conditions are acceptable for an engine retarder to operate. Operation of the retarder is inhibited during undesirable engine operating conditions (such as while the engine is being fueled).With the Cruise Control ON/OFF Switch in the OFF position, the retarder is enabled under the following conditions:* engine rpm is greater than 950 rpm and* driver's foot is off the throttle pedal and the clutch pedalWith the Cruise Control ON/OFF Switch "ON", the operation of the retarder is also controlled through the customer parameter "Engine Retarder Mode". Programming the parameter to "COAST" allows retarding with the service brakes applied, but allows the engine to coast with no retarding after they are released. Programming the parameter to "LATCH" allows retarding with the service brake applied and keeps the retarder latched on after the service brakes are released (until engine rpm drops below 950 rpm or the driver presses the throttle or clutch pedal).The Retarder Enable Signal should be 15% Duty Cycle (nominal) to indicate that the retarder is enabled and 85% Duty Cycle (nominal) to indicate that it is disabled. The remainder of the engine retarder circuit is supplied by the OEM. In typical installations, the Retarder Enable signal isused by a separate Brake Control Module, which then energize the retarder solenoids. An "Engine Brake On" Switch is also typically connected to the Brake Control Module, and must be ON before the brake will operate. Step 1. Inspect Connectors And Wiring HarnessInspect the Vehicle Connector (J7/P7) and the ECM Connector (J4/P4) connections and wiring between, being sure to:* Check Connector lock rings.* Perform 10 pound pull test on each pin or wire.* Inspect wiring for damage or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details. Repair any damage, then continue with the next step.Step 2. Verify Throttle Position And Clutch Switch InputsA. Use P-303: Throttle Position Sensor Adjustment procedure to verify correct adjustment of the throttle pedal. The "Throttle Position Signal" must be less than 7% at low idle, to perform the remainder of this test procedure.B. Use P-215: Service Brake And Clutch Switch Test, to verify correct adjustment and operation of the Clutch Pedal Switch. Clutch Switch Status must be OFF, with foot off the clutch, to perform the remainder of this test procedure.Step
The "Retarder Enable" signal is provided by the ECM to indicate that conditions are acceptable for an engine retarder to operate. Operation of the retarder is inhibited during undesirable engine operating conditions (such as while the engine is being fueled).With the Cruise Control ON/OFF Switch in the OFF position, the retarder is enabled under the following conditions:* engine rpm is greater than 950 rpm and* driver's foot is off the throttle pedal and the clutch pedalWith the Cruise Control ON/OFF Switch "ON", the operation of the retarder is also controlled through the customer parameter "Engine Retarder Mode". Programming the parameter to "COAST" allows retarding with the service brakes applied, but allows the engine to coast with no retarding after they are released. Programming the parameter to "LATCH" allows retarding with the service brake applied and keeps the retarder latched on after the service brakes are released (until engine rpm drops below 950 rpm or the driver presses the throttle or clutch pedal).The Retarder Enable Signal should be 15% Duty Cycle (nominal) to indicate that the retarder is enabled and 85% Duty Cycle (nominal) to indicate that it is disabled. The remainder of the engine retarder circuit is supplied by the OEM. In typical installations, the Retarder Enable signal isused by a separate Brake Control Module, which then energize the retarder solenoids. An "Engine Brake On" Switch is also typically connected to the Brake Control Module, and must be ON before the brake will operate. Step 1. Inspect Connectors And Wiring HarnessInspect the Vehicle Connector (J7/P7) and the ECM Connector (J4/P4) connections and wiring between, being sure to:* Check Connector lock rings.* Perform 10 pound pull test on each pin or wire.* Inspect wiring for damage or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details. Repair any damage, then continue with the next step.Step 2. Verify Throttle Position And Clutch Switch InputsA. Use P-303: Throttle Position Sensor Adjustment procedure to verify correct adjustment of the throttle pedal. The "Throttle Position Signal" must be less than 7% at low idle, to perform the remainder of this test procedure.B. Use P-215: Service Brake And Clutch Switch Test, to verify correct adjustment and operation of the Clutch Pedal Switch. Clutch Switch Status must be OFF, with foot off the clutch, to perform the remainder of this test procedure.Step
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Mitsubishi
Mitsubishi
106876-2040
INJECTION-PUMP ASSEMBLY