Information injection-pump assembly
ZEXEL
106961-1700
1069611700
Rating:
Service parts 106961-1700 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
3.
GOVERNOR
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-138-2
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106961-1700
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106961-1700
1069611700
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 (drive side)
134424-3520
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
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
1-8-7-6-
5-4-3-10
-9-2
Pre-stroke
mm
4
3.97
4.03
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25
Cal 1-8 deg. 27 26.75 27.25
Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25
Cal 1-7 deg. 72 71.75 72.25
Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25
Cal 1-6 deg. 99 98.75 99.25
Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25
Cal 1-5 deg. 144 143.75 144.25
Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25
Cal 1-4 deg. 171 170.75 171.25
Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25
Cal 1-3 deg. 216 215.75 216.25
Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25
Cal 1-10 deg. 243 242.75 243.25
Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25
Cal 1-9 deg. 288 287.75 288.25
Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
83.5
82
85
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.2
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
96.3
94.3
98.3
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.8+-0.5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
96.8
92.8
100.8
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
5.6+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8
6.6
9.4
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Injection quantity adjustment_05
Adjusting point
F
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
125
125
Fixing the lever
*
Remarks
When manual lever is on the boost side
When manual lever is on the boost side
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Supplied with damper spring not set.
(4)Supply solenoid operating voltage DC24V and move the solenoid body so that the excess lever reaches the excess position at the solenoid's maximum stroke.
(5)At excess fuel lever operation: not exceeding EXL
(6)Excess fuel setting for starting: SXL
----------
RT=0.8 TH=2.7mm EXL=2mm SXL=9.7+-0.1mm
----------
----------
RT=0.8 TH=2.7mm EXL=2mm SXL=9.7+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(7.5)deg t1=1.5--sec. t2=1.5--sec.
----------
N1=1100++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7.5+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(7.5)deg t1=1.5--sec. t2=1.5--sec.
----------
N1=1100++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7.5+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=9deg+-5deg
----------
----------
a=9deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=40mm
----------
a=10deg+-5deg b=32deg+-3deg
----------
aa=40mm
----------
a=10deg+-5deg b=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
0000001101
N:Normal
B:When boosted
----------
----------
a=(5deg) b=(24deg)
----------
----------
a=(5deg) b=(24deg)
0000001501 RACK SENSOR
V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa
(4)-
----------
aa=13deg
----------
a=(170deg)
----------
aa=13deg
----------
a=(170deg)
Information:
Illustration 1 g01046024
Engine with two turbochargers (1) Inlet valves (2) Exhaust valves (3) Inlet manifold (4) Exhaust manifold (5) Water inlet for the aftercooler (6) Water outlet for the aftercooler (7) Aftercooler (8) Air inlet (9) Exhaust outlet (10) Compressor (11) TurbineThe components of the air inlet and exhaust system control the quality of air and the amount of air that is available for combustion. The components of the air inlet and exhaust system are the following components:
Air cleaner
Turbocharger
Aftercooler
Cylinder head
Valves and valve system components
Piston and cylinder
Inlet manifold
Exhaust manifoldNote: The following description of the operation of the air inlet and exhaust system assumes that the engine is developing boost pressure. Inlet air passes through the air cleaner into the air inlet (8) of the turbocharger compressor wheel (10). The turbocharger will supply more volume of air into the engine. This compressing of the air is referred to as boost. The compressing of air causes the air temperature to rise to about 204 °C (400 °F). As the air flows through the aftercooler (7) the temperature of the compressed air lowers to about 46 °C (115 °F). Cooling of the inlet air causes the air to become more dense. This increases combustion efficiency and this increases horsepower output.From the aftercooler, air enters the inlet manifold (3). Air flow from the inlet manifold (3) into the cylinders is controlled by inlet valves (1). There are two inlet valves and two exhaust valves (2) for each cylinder. The inlet valves open at the top center position before the piston moves toward the bottom center position. This is called the inlet stroke. When the inlet valves open, cooled compressed air from the inlet port enters the cylinder. The inlet valves close as the piston reaches the bottom center position. The piston begins to travel back to the top center position on the compression stroke. The air in the cylinder is compressed to a very high temperature. When the piston is near the end of the compression stroke, fuel is injected into the cylinder and mixes with the air. This causes combustion to start in the cylinder. Once combustion starts, the combustion force pushes the piston toward the bottom center position. This is called the power stroke. The exhaust valves open when the piston moves toward the bottom center position and the exhaust gases are pushed through the exhaust port into exhaust manifold (4) as the piston travels toward top center on the exhaust stroke. The exhaust valves close and the cycle starts again. The complete cycle consists of four strokes:
Inlet
Compression
Power
ExhaustExhaust gases from the exhaust manifold (4) enter the turbine side of the turbocharger. The exhaust gas temperature causes the turbine wheel (11) in the turbocharger to turn. The turbine wheel is connected to the shaft that drives the compressor wheel. Exhaust gases from the turbine wheel exit the turbocharger (9) .Turbocharger
Illustration 2 g01361124
Water cooled turbocharger (8) Air inlet (9) Exhaust outlet (11) Exhaust inlet (12) Compressor housing (13) Compressor wheel (14) Bearing (15) Oil Inlet