Information injection-pump assembly
ZEXEL
106673-7002
1066737002
Rating:
Service parts 106673-7002 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME151161
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
106673-7002
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106673-7002
1066737002
Zexel num
Bosch num
Firm num
Name
106673-7002
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
1-5-3-6-
2-4
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
172
167.7
176.3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8+-0.5
Pump speed
r/min
385
385
385
Each cylinder's injection qty
mm3/st.
21
17.8
24.2
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
172
171
173
Basic
*
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
163
159
167
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.85
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
167
161
173
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
(R2-1.65
)
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1-1.
5)
Boost pressure
kPa
16
16
16
Boost pressure
mmHg
120
120
120
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
(4)Damper spring setting
----------
T1=AC44 BCL=(1.65)+-0.1mm
----------
----------
T1=AC44 BCL=(1.65)+-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=1-0.2(mm) N2=800r/min C2=(10deg) t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2(mm) N2=800r/min C2=(10deg) t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=0deg+-5deg b=36deg+-3deg
----------
aa=37.5mm
----------
a=0deg+-5deg b=36deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.)
(2)Normal engine position (equivalent to R = cc).
(3)Use the hole above R = dd
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
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=7.6+-0.1mm
----------
----------
N1=325r/min Ra=7.6+-0.1mm
----------
0000001601 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(13.4)+1.1mm
----------
----------
N1=1100r/min Ra=R1(13.4)+1.1mm
----------
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=5deg
----------
a=(2deg)
----------
aa=5deg
----------
a=(2deg)
Information:
Start By:a. remove flywheelb. remove crankshaft rear seal and wear sleeve **Remove the crankshaft rear seal and wear sleeve only if the engine is equipped with the later design seal. The later design seal can be identified by the rotation marks on the seal.
Some flywheel housings will have more bolts holding the flywheel housing to the cylinder block.
1. If the engine is equipped with an electric starting motor, remove the electric starting motor from the flywheel housing.2. Remove the bolts that hold the oil pan plate to the flywheel housing. Loosen the bolts that hold the oil pan plate to the cylinder block.3. Install spacers between the oil pan plate and the cylinder block to hold the oil pan plate away from the flywheel housing.
3306 Engine Shown4. On 3306 Engines, remove turbocharger oil drain pipe (1).5. Install Tool (A) on the flywheel housing as shown, and fasten a hoist to it.6. Remove all bolts (2) and the flywheel housing from the engine. The weight of the flywheel housing is 37 kg (82 lb).Install Flywheel Housing
3306 Engine Shown1. Install Tool (A) on the flywheel housing. Fasten a hoist to the flywheel housing. 2. Put the gasket and flywheel housing in position on the engine. Install bolts (2) that hold it. Tighten the bolts to a torque of 100 14 N m (74 10 lb ft) as shown.3. Remove Tool (A) from the flywheel housing.4. On 3306 Engines, install turbocharger oil drain line (1).5. Cut the bottom of the flywheel housing gasket off even with the cylinder block and flywheel housing. Put 3S6252 RTV Silicone Adhesive/Sealant on the bottom of the gasket where it makes contact with the oil pan plate gasket.6. Remove the spacers from between the oil pan plate and the cylinder block. Install the bolts that hold the oil pan plate to the flywheel housing. Tighten the bolts that hold the oil pan plate to the cylinder block.7. If the engine is equipped with an electric starting motor, install it on the flywheel housing.End By:a. install crankshaft rear seal and wear sleeveb. install flywheel
Some flywheel housings will have more bolts holding the flywheel housing to the cylinder block.
1. If the engine is equipped with an electric starting motor, remove the electric starting motor from the flywheel housing.2. Remove the bolts that hold the oil pan plate to the flywheel housing. Loosen the bolts that hold the oil pan plate to the cylinder block.3. Install spacers between the oil pan plate and the cylinder block to hold the oil pan plate away from the flywheel housing.
3306 Engine Shown4. On 3306 Engines, remove turbocharger oil drain pipe (1).5. Install Tool (A) on the flywheel housing as shown, and fasten a hoist to it.6. Remove all bolts (2) and the flywheel housing from the engine. The weight of the flywheel housing is 37 kg (82 lb).Install Flywheel Housing
3306 Engine Shown1. Install Tool (A) on the flywheel housing. Fasten a hoist to the flywheel housing. 2. Put the gasket and flywheel housing in position on the engine. Install bolts (2) that hold it. Tighten the bolts to a torque of 100 14 N m (74 10 lb ft) as shown.3. Remove Tool (A) from the flywheel housing.4. On 3306 Engines, install turbocharger oil drain line (1).5. Cut the bottom of the flywheel housing gasket off even with the cylinder block and flywheel housing. Put 3S6252 RTV Silicone Adhesive/Sealant on the bottom of the gasket where it makes contact with the oil pan plate gasket.6. Remove the spacers from between the oil pan plate and the cylinder block. Install the bolts that hold the oil pan plate to the flywheel housing. Tighten the bolts that hold the oil pan plate to the cylinder block.7. If the engine is equipped with an electric starting motor, install it on the flywheel housing.End By:a. install crankshaft rear seal and wear sleeveb. install flywheel
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106673-7002
INJECTION-PUMP ASSEMBLY