106673-7190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737190

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7190 1066737190

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Cross reference number

ZEXEL 106673-7190 1066737190

Zexel num

Bosch num

Firm num

Name

106673-7190

INJECTION-PUMP ASSEMBLY

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 131424-4620

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 149 146 152

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_02

Adjusting point B

Rack position 4.7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 5.4 10.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 105 145

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-1.2

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(9)

Boost pressure kPa 26.7 20 33.4

Boost pressure mmHg 200 150 250

Timer adjustment

Pump speed r/min 825--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 775

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 975

Advance angle deg. 1 0.5 1.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke
----------
K=13
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=20deg+-5deg b=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Stopper bolt setting
----------
aa=0r/min bb=1-0.5mm
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a=35deg+-5deg b=70deg+-5deg

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=13deg
----------
a=(7deg)

Information:

14. Put clean engine oil on the camshaft bearings and on camshaft (21). Install camshaft as shown. 15. Install camshaft gear (22) and retainer (23). Install the three bolts. 16. Put clean engine oil on lifters (25). Install lifters (25) and spacers (24) for each of the injection pumps. Be sure the lifters and spacers are put in their original location. 17. Put clean engine oil on the left and right fuel racks. Install left rack in the pump housing with the groove in the rack engaged with the tab of the rack bearing. Install right rack (26) with the groove in the rack engaged with the tab of the rack bearing. 18. Install dowel (27) in the pump housing until it is extended 12.2 0.5 mm (.48 .02 in) from the surface of the pump housing.19. Install link (29) and bracket assembly (30). Install bolt (28). Be careful so bracket (30) does not turn as bolt (28) is tightened. 20. Install Tool (E) in the injection pump housing to hold the racks in the center (zero) position.21. Put the space in gear segment (32) in alignment with the groove in pump barrel (31). Put the injection pump straight down into the housing bore with the space in gear segment (32) engaged with the pin in the lifter and the groove in barrel (31) engaged with the dowel in the pump housing. Use Tool (F) to install the pump. 22. Install seal (33) and bushing (34) in the pump housing bore. If the injection pump is in the correct position, bushing (34) will turn into the threads of the pump housing with the fingers until it is even with the housing.23. Tighten bushings (34) to a torque of 205 14 N m (150 10 lb ft) with Tool (G). 24. Install a felt washer (35) and protection caps for each injection pump. For more detail see the topic "Install Fuel Injection Pumps" in this module. 25. Heat gear (36) to a maximum temperature of 232°C (450°F) and install it on the shaft. 26. Install bearing in housing (37) with Tooling (C). 27. Install shaft and gear assembly (40) in fuel injection housing. Install gasket (39) on housing. Install small cover (38). Install housing (37) on fuel injection housing with the bolts that hold it. 28. Install fuel transfer pump (41) in housing (37) with the bolts that hold it. 29. If replacement of the dowels (43) in the governor plate is necessary, see illustration A42792P1 for correct installation dimensions. 30. Install bearing (42) for drive gear with Tooling (C) until it is 0.51 mm (.020 in) from the top surface of the governor plate. 31. Install drive gear (44), install ring (45) with Tool (H). 32. Install O-ring seals (47) on cylinder (46). 33. Install cylinder (46) in governor plate with the notch in the cylinder in alignment with the bolt hole in the governor plate. 34. Install O-ring seal (49) on sleeve (51).