Information injection-pump assembly
ZEXEL
106673-7003
1066737003
Rating:
Service parts 106673-7003 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:
106673-7003
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106673-7003
1066737003
Zexel num
Bosch num
Firm num
Name
106673-7003
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
13.1
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
163
158.9
167.1
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(13.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
163
162
164
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.
156.5
152.5
160.5
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.
157.5
151.5
163.5
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.
6)
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=AC88 BCL=1.65+-0.1mm
----------
----------
T1=AC88 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=1-0.2mm 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=1-0.2mm 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=2deg+-5deg b=37deg+-3deg
----------
aa=37.5mm
----------
a=2deg+-5deg b=37deg+-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 (Rack position corresponding to cc)
(3)Use the hole above R = dd
----------
aa=1100mm bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
----------
aa=1100mm bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
0000001501 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(13.1)+1.1mm
----------
----------
N1=1100r/min Ra=R1(13.1)+1.1mm
----------
0000001601 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
----------
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:
2. Loosen clamp (1).3. Remove two bolts (2).4. Remove two bolts (3) and washers.5. Remove water pump (4) and the gasket. When installing replace the gasket. Make sure all gasket surfaces are clean and free of dirt. For installation of the water pump, reverse the removal steps.6. Fill the radiator with coolant to the proper level. See the Operation & Maintenance Manual.Disassemble & Assemble Water Pump
The following tools are needed for disassembly. Start By:a. remove water pump 1. Remove bolt (15) and the washer. Remove bearing (12) and gear (10) as a unit.2. Use Tool (A), (C) and a press, and remove bearing (12) from gear (10).3. Remove snap ring (8) with Tool (B).4. Remove two bolts (1), the washers, cover (14) and gasket (2) from water pump housing (18).5. Loosen bolt (13) approximately 6.4 mm (.25 in). Hit the bolt with a soft hammer to loosen impeller (16) from shaft (9).6. Remove bolt (13), washer (11), impeller (16), spring (3) and seal assembly (4) from shaft (9).7. Remove bearing (7) and shaft (9) as a unit.8. Use Tool (A), (C) and a press to remove bearing (7) from shaft (9).9. Remove ceramic seal (5) and seal (17) from water pump housing (18).10. Use Tool (C) to remove lip-type seal (6) from the water pump housing. The following steps are for assembly of the water pump. The following tools are needed for assembly. 11. Install lip-type seal (6) in water pump housing (18) with Tool (C). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal.12. Install shaft (9) in bearing (7) with a press.13. Install shaft (9) and bearing (7) as a unit in water pump housing (18).14. Install snap ring (8) with Tool (B).
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
15. Put ceramic ring (5) in position in seal (17). Use hand pressure and Tool (D) to install the ceramic ring.16. Remove spring (3) from seal assembly (4). Use hand pressure and Tool (D) to install the seal assembly. Push seal assembly (4) on shaft (9) until it makes light contact with ceramic ring (5).17. Install spring (3) on seal assembly (4). Put impeller (16) in position on shaft (9), and install washer (11) and bolt (13) that hold it. Tighten bolt (13) to a torque of 38.0 1.5 N m (28 1 lb ft).18. Put gasket (2) and cover (14) in position on water pump housing (18). Install the two washers and bolts (1) that hold them.19. Install bearing (12) on gear (10) with a press.20. Position gear (10) and bearing (12) as a unit on shaft (9). Install the washer and bolt (15) that hold them together. Tighten bolt (15) to a torque of
The following tools are needed for disassembly. Start By:a. remove water pump 1. Remove bolt (15) and the washer. Remove bearing (12) and gear (10) as a unit.2. Use Tool (A), (C) and a press, and remove bearing (12) from gear (10).3. Remove snap ring (8) with Tool (B).4. Remove two bolts (1), the washers, cover (14) and gasket (2) from water pump housing (18).5. Loosen bolt (13) approximately 6.4 mm (.25 in). Hit the bolt with a soft hammer to loosen impeller (16) from shaft (9).6. Remove bolt (13), washer (11), impeller (16), spring (3) and seal assembly (4) from shaft (9).7. Remove bearing (7) and shaft (9) as a unit.8. Use Tool (A), (C) and a press to remove bearing (7) from shaft (9).9. Remove ceramic seal (5) and seal (17) from water pump housing (18).10. Use Tool (C) to remove lip-type seal (6) from the water pump housing. The following steps are for assembly of the water pump. The following tools are needed for assembly. 11. Install lip-type seal (6) in water pump housing (18) with Tool (C). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal.12. Install shaft (9) in bearing (7) with a press.13. Install shaft (9) and bearing (7) as a unit in water pump housing (18).14. Install snap ring (8) with Tool (B).
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
15. Put ceramic ring (5) in position in seal (17). Use hand pressure and Tool (D) to install the ceramic ring.16. Remove spring (3) from seal assembly (4). Use hand pressure and Tool (D) to install the seal assembly. Push seal assembly (4) on shaft (9) until it makes light contact with ceramic ring (5).17. Install spring (3) on seal assembly (4). Put impeller (16) in position on shaft (9), and install washer (11) and bolt (13) that hold it. Tighten bolt (13) to a torque of 38.0 1.5 N m (28 1 lb ft).18. Put gasket (2) and cover (14) in position on water pump housing (18). Install the two washers and bolts (1) that hold them.19. Install bearing (12) on gear (10) with a press.20. Position gear (10) and bearing (12) as a unit on shaft (9). Install the washer and bolt (15) that hold them together. Tighten bolt (15) to a torque of
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106673-7003
INJECTION-PUMP ASSEMBLY