106673-7200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7200 1066737200

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Service parts 106673-7200 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0200

3. GOVERNOR 105923-1641

4. SUPPLY PUMP

105237-4790

5. AUTOM. ADVANCE MECHANIS 105691-3802

6. COUPLING PLATE 105663-0800

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7371

11. Nozzle and Holder ME151161

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-4111

14. NOZZLE

15. NOZZLE SET 105019-0330

Include in #1:

106673-7200 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-7200 1066737200

Zexel num

Bosch num

Firm num

Name

106673-7200

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 105780-8250

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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 -

Rack position 12.9

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 147 143.3 150.7

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(12.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 147 146 148

Basic *

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 143.5 139.5 147.5

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.75 )

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 142 136 148

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_06

Adjusting point D

Rack position (R2-1.3)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 104.5 102.5 106.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position (R2-1.3)

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1)

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

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=AC25 BCL=(1.3)+-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=(10)deg 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=1deg+-5deg b=(39deg)+-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)

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(12.9)+1.05mm
----------

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)

Information:

2. Remove three nuts and washers (1).3. Move Peec unit (2) out of the way. (If so equipped). 4. Remove elbows (5) and pipes (7).5. Remove fuel line brackets (4).6. Remove bolts (6). Remove cover (3). 7. Remove elbows (10). Remove adapters (8) and adapters (9) from the aftercooler core. Remove bolts (11). 8. Move aftercooler core (12) toward the front of the engine and use two people to remove the aftercooler core from the lower aftercooler housing. The weight of the aftercooler core is approximately 29 kg (65 lb). Remove the O-ring seals from the aftercooler core extensions.Install Aftercooler
1. Install O-ring seals (13) on the aftercooler core extensions. Put clean engine oil or glycerin on the seals.2. Use two people to put aftercooler core (12) into position in the lower aftercooler housing. The weight of the aftercooler core is approximately 29 kg (65 lb). 3. Install bolts (11). Put clean engine oil or glycerin on O-ring seal (14) and in bores (15) and (16). 4. Put clean engine oil or glycerin on O-ring seals (17) and adapters (8) and (9). Install adapters (8) and (9) in the aftercooler core. 5. Install elbows (10). 6. Put cover (3) into position on the engine. Install bolts (6).7. Install fuel injection line brackets (4). Tighten bolts (20) to a torque of 4.5 1.1 N m (40 10 lb in).8. Put clean engine oil or glycerin on pipes (7). Install pipes (7) and elbows (5).9. Fill the cooling system with coolant. See Operation & Maintenance Manual for the proper procedure and levels.