106673-7380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7380 1066737380

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Service parts 106673-7380 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0350

3. GOVERNOR 105952-1710

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:

106673-7380 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-7380 1066737380

Zexel num

Bosch num

Firm num

Name

106673-7380

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

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

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

Rack position (12.3)

Vist V 1.54 1.54 1.54

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 154 153 155

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Injection quantity adjustment_02

Rack position (6.2)

Vist V 2.8 2.7 2.9

Pump speed r/min 405 405 405

Average injection quantity mm3/st. 15.8 13.8 17.8

Max. variation between cylinders % 0 -15 15

Test data Ex:

Governor 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.
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L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
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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

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=16mm bb=1mm
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a=19deg+-5deg b=29deg+-5deg

0000000901

(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
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a=(2deg)

Stop lever angle

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001201 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 (154610-0620) (1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01. (2)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)
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V1=1V
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Information:

1. Remove oil supply tube (1) and suction bell and tube (2). 2. Remove bolts (3) that hold the oil pump to the cylinder block and remove oil pump (4).3. To install, put oil pump (4) in position on the cylinder block. Install the bolts that hold the oil pump to the cylinder block.4. Put clean engine oil on the O-ring seals of the tubes.5. Install oil supply tube (1), suction bell and tube (2).End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove the bolt and washer that hold the gear on the shaft.2. Use Tool (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve. Remove the spring and the bypass valve.4. Remove cover (2) from the pump body. 5. Use Tool (B) and remove the bearings from the cover. 6. Remove gears (5) from pump body (4).7. Use Tool (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use Tool (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 15 degrees from the center line of the oil pump outlet passage (2). 2. Install idler gear and drive gear (5) in the oil pump body (4). Put clean engine oil on the bearings and the gears. 3. Use Tool (A) and install the bearings in cover (2). Install the bearings so the joint of the bearing bores toward oil pump outlet passage (6).4. Install bypass valve (7), spring (8) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump