106673-7281 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737281

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7281 1066737281

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Service parts 106673-7281 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0070

3. GOVERNOR 105923-1851

4. SUPPLY PUMP

105237-4790

5. AUTOM. ADVANCE MECHANIS 105681-1870

6. COUPLING PLATE 105663-0820

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7251

11. Nozzle and Holder ME150945

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105041-4110

14. NOZZLE

15. NOZZLE SET 105019-0420

Include in #1:

106673-7281 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-7281 1066737281

Zexel num

Bosch num

Firm num

Name

106673-7281

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 13.2

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 153.5 149.7 157.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8.6+-0.5

Pump speed r/min 360 360 360

Each cylinder's injection qty mm3/st. 15.8 13.4 18.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.2)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 153.5 152.5 154.5

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 151.5 147.5 155.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point D

Rack position R3-1.2

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 92.5 88.5 96.5

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 R3-1.2

Boost pressure kPa 4 3.3 4.7

Boost pressure mmHg 30 25 35

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R3(R1-1. 3)

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Remarks
Finish

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=AD44 BCL=1.2+-0.1mm
----------

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=0.5deg+-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=41deg+-5deg b=29.5deg+-5deg c=(16.5deg)

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=8.1+-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=8deg
----------
a=(2deg)

Information:

Transmission Oil Cooler
The machine is equipped with a power shift transmission. A transmission oil cooler is installed in the outlet section of the radiator. The radiator coolant flows around the tubes of the cooler and cools the transmission oil as it flows through the cooler. The transmission oil then returns to the transmission inlet.Lubrication System
Oil Pump
(1) Strainer. (2) Oil pump relief valve. (3) Oil pump. (4) Idler gear. (5) Crankshaft gear.The lubrication system is the pressure type and the flow of oil goes from the oil pan through strainer (1) into oil pump (3). Oil pump (3) is driven by crankshaft gear (5) through the idler gear (4). The oil pump is connected to the front main bearing cap. Relief valve (2) which is spring loaded controls the maximum oil pressure. An oil pressure sending unit is connected to the main oil gallery.Oil under pressure goes from the oil pump through the relief valve, oil filter and into the main oil gallery that is a drilled passage the length of the crankcase. From the gallery the oil flows through drilled passages to the main bearing bores and then through the crankshaft passages to the big end (rod) bearings. The small end (rod) bearings, cylinder liners and pistons get splash lubrication from the big end (rod) bearings.The camshaft front bearing and journals are lubricated from numbers 1, 3 and 5 main bearings. The camshaft center journal supplies a controlled amount of oil to the rocker shaft assembly. Oil from the rocker shaft drains through a bleed hole in each rocker lever to lubricate the valves, guides, tappets (valve lifters) and cam lobes.
Timing Gears
(6) Idler gear. (7) Idler gear retainer plate.Oil also goes from the gallery through the rear of idler gear (6) hub, then through passages to lubricate the idler gear bearing and gear retainer plate (7). On engines equipped with hydraulic governed fuel injection pumps, the fuel pump adapter plate is also lubricated from the main oil gallery. The timing gears are splash lubricated from the idler gear hub.
Oil Lubrication SchematicAir Inlet And Exhaust System
Air Inlet Components
(1) Intake manifold. (2) Exhaust manifold.
Air Inlet Components
(3) Air cleaner.The air inlet and exhaust system components are: air cleaner (3), intake manifold (1), an air inlet hose, an air indicator, the cylinder head valves and valve mechanism components, exhaust manifold (2), pipe and muffler.Air is pulled in the air inlet system by the intake stroke of the piston. The air flows in air cleaner (3), through air inlet hose that directs the volume of air to intake manifold (1). The air flows through intake manifold (1) which directs even distribution of the air to each cylinder where the air is mixed with fuel from the injectors. The sequence and action of the engines' four cylinders and four strokes, (compression, power, exhaust and intake) give constant air flow to the intake system for engine operation.An air indicator located on the air inlet hose shows a red indication when too much air restriction (dirt)