106673-7211 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737211

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7211 1066737211

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Service parts 106673-7211 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-1280

3. GOVERNOR 105923-1652

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:

106673-7211 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-7211 1066737211

Zexel num

Bosch num

Firm num

Name

106673-7211

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 105780-8250

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 13.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 172.5 168.2 176.8

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 410 410 410

Each cylinder's injection qty mm3/st. 26 22.1 29.9

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. 172.5 171.5 173.5

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+0.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 161.5 157.5 165.5

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. 172.5 166.5 178.5

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 R2-1.6

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. 75)

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=AE17 BCL=1.6+-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=(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=2deg+-5deg b=39.5deg+-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+0.9mm
----------

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:

Start By:a. remove rocker shaft assembliesb. remove turbochargers1. Remove the valve cover bases from the cylinder head. 2. Remove sensor (7) from cylinder head (8). If necessary, remove the O-ring seal from sensor (7).3. Remove bolt and locknut (5).4. Disconnect connector (6).5. Remove bolt (4) and sensor (3). If necessary, remove the O-ring seal from sensor (3).6. Remove three bolts (2) and water lines group (1). 7. Remove bolt (9) from timing advance housing.8. Remove bolt (10) and support (11). 9. Remove the bolt and support (12). Remove the remaining ten bolts and the supports along the intake side of the cylinder head.10. Disconnect hose clamp (13) from the exhaust manifold. 11. Attach Tool (A) and fasten a hoist.12. Remove bolts (14) and remove the cylinder head. The weight of the cylinder head is approximately 172 kg (380 lb).13. Remove the head gasket and the water seals.
Do not put the cylinder head down on a flat surface. Direct injection nozzles extend out from the bottom surface of the cylinder head and will be damaged by the weight of the head.
Install Cylinder Head
1. Thoroughly clean the bottom surface of the cylinder head. Install a new head gasket and water seals. Do not use any adhesives. A new spacer plate gasket must be used when the cylinder head is installed. See the topic "Remove & Install Spacer Plate" in this module. 2. Attach Tool (D) and fasten a hoist.3. Install the cylinder head to the block. The weight of the cylinder head is approximately 172 kg (380 lb).
(1) Large bolts (3/4 inch). Put 6V-4876 Molycoat Paste Lubricant on bolt threads and between washer and underside of bolt heads. (2) Small bolts (3/8 inch). See Step 4h.4. Use the tightening sequence below to tighten the bolts that hold the cylinder head in position. a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves and the remaining (3/4 in) bolts.e. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).h. Tighten the thirteen small bolts (2) to a torque of 45 7 N m (33 5 lb ft). 5. Install support (12).6. Connect hose clamp (13) to exhaust manifold. 7. Install bolt (10) and support (11). Install the remaining ten bolts and the supports along the intake side of the cylinder head. Torque all twelve bolts (10) to 43 7 N m (32 5