106673-2331 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066732331

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-2331 1066732331

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Service parts 106673-2331 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5770

3. GOVERNOR 105952-0502

4. SUPPLY PUMP 105237-1840

5. AUTOM. ADVANCE MECHANIS 105681-8000

6. COUPLING PLATE 105664-0650

7. COUPLING PLATE

8. _ 159590-1621

9. _

10. NOZZLE AND HOLDER ASSY 105100-7861

11. Nozzle and Holder ME120371

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105030-4250

14. NOZZLE 105015-8221

15. NOZZLE SET

Include in #1:

106673-2331 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-2331 1066732331

Zexel num

Bosch num

Firm num

Name

106673-2331

INJECTION-PUMP ASSEMBLY
14CA PE6P,6PD PE

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-7220

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

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 21

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Rack position (13)

Vist V 1.41 1.41 1.41

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 159.5 158.5 160.5

Max. variation between cylinders % 0 -2 2

Basic *

PS407980-224* V V1+0.13

PS407980-224* mm 5.4+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_02

Rack position (6.5)

Vist V 2.7 2.6 2.8

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 11.4 9.4 13.4

Max. variation between cylinders % 0 -15 15

PS407980-224* V V1+0.13

PS407980-224* mm 5.4+-0.0 3

Governor adjustment

Pump speed r/min 700--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 650

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min 850

Advance angle deg. 2 1.5 2.5

Remarks
Finish

0000001201

Pre-stroke mm 5.6 5.57 5.63

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 5 4.5 5.5

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1 1 1.05

Adjustment *

Remarks
Output voltage V1

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.6 2.32 2.88

Output voltage V 2.8 2.78 2.87

Confirmation *

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=16mm bb=1mm
----------
a=19deg+-5deg b=29deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.6+-0.03mm
----------
a=(2deg)

0000001701

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------

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Information:

Camshaft
When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.Camshaft bearing journals have a diameter of 2.5000 .0005 in. (63.500 0.013 mm) and the minimum diameter worn is 2.4970 in. (63.424 mm).To find lobe lift (A) of camshaft, use the following procedure:1. Measure lobe height (B) of one exhaust and one intake lobe.2. Measure base circle (C) of one exhaust and one intake lobe.3. Subtract base circle (C) dimension (STEP 2) from lobe height (B) dimension (STEP 1). The difference is actual lobe lift (A).4. The specified (new) lobe lift (A) is: (a) Exhaust lobe ... .3071 in.(7.800 mm)(b) Intake lobe ... .3077 in.(7.816 mm)5. The maximum permissible difference between actual lobe lift (STEP 3) and specified lobe lift (STEP 4) is .025 in. (0.64 mm).
CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.With camshaft installed in the cylinder block, check end play. End play with new components should be .007 .003 in. (0.18 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).Camshaft Followers
Use an 8S2293 Magnet to remove the cam followers.
REMOVING CAM FOLLOWERSCam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers. Use new cam followers with a new camshaft.Camshaft Gears
1. Remove screw (1) and washer (2) from end of camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.2. Remove timing advance unit from the camshaft.3. Install puller (A), with spacer (C) over the shaft in the camshaft spacer (B) on spacer (C) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.To install the gear use the following procedure:1. Heat the gear to a temperature of approximately 400°F (204°C) before installing on the camshaft.
Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 600°F (315°C). Heating the gear with a torch or to a temperature of more than 600°F (315°C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completly seated against the shoulder of the camshaft.
Do not drive the gear on the camshaft.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (3) in washer with hole (4) in camshaft and install washer (2).5. Install screw (1) and