106673-7410 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737410

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7410 1066737410

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Service parts 106673-7410 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0200

3. GOVERNOR 105923-2110

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:

106673-7410 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106673-7410 1066737410

Zexel num

Bosch num

Firm num

Name

106673-7410

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 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(12 .9)-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=(10deg) 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)Use the hole at R = aa (2)Normal engine position (Rack position corresponding to bb) (3)Set the stopper bolt so that speed = cc and rack position = dd and confirm non-injection.
----------
aa=54mm bb=18mm cc=1100r/min dd=3.5+-0.3mm
----------
a=(20.5deg) b=29.5deg+-5deg c=40deg+-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=7.6+-0.1mm
----------

0000001601 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:

Typical Example2. Remove eight bolts (3) that fasten pipe (1) to the elbow. Remove four bolts (2) that fasten the elbow to the aftercooler cover. Remove elbow (4).
Typical Example3. Remove bracket (5) from the oil filter tube and the oil level gauge group.
Typical Example4. Remove four bolts (7) from the air inlet elbow. Remove plate (6) and elbow (8). 5. Remove two tubes (10) from the air compressor to the aftercooler.6. Remove elbows (9) from the aftercooler housing.
Typical Example
Put identification on bolts (12) because they are 6.4 mm (.25 in) longer than all other bolts. They must be installed in the same location.
7. Remove bolts (11) and (12) from cover, and remove the cover.
Put identification on bolt (14) because it is 12.7 mm (.50 in) shorter than all the other bolts. It must be installed in the same location. Remove four adapters (15). Put plugs in both holes in the aftercooler core assembly. This will keep coolant out of the engine intake manifold.
8. Remove bolts (13) and (14) that hold the core assembly in position.9. Remove the aftercooler core assembly. 10. Remove air line (17) from the fuel ratio control valve.11. Remove eight bolts (16). Remove housing assembly (18).Install Aftercooler
1. Check all seals and gaskets for damage. If damaged, use new parts for replacement.
All foreign material and dirt must be removed from the gasket surface and inside the housing and intake manifold.
2. Install housing (1) and air line (2) to the fuel control valve. 3. Install four new seals (3) on the core assembly. Put clean glycerin on the O-ring seals. 4. Install core assembly (4) inside the housing. Remove plugs in both holes of the aftercooler core assembly. Install the bolts that fasten the core to housing. Install the bolts in their original location. 5. Put clean engine oil in the bores of the adapters. Install adapters (5). 6. Put cover (6) in position on the aftercooler. Install the two bolts in position (7). These bolts are 6.4 mm (.25 in) longer than all other bolts around the housing. Install the remainder of the bolts around the housing. 7. Install elbows (8). 8. Install two tubes (9) between the air compressor and the aftercooler.
Typical Example9. Install elbow (10) and plate (11) on the aftercooler cover. Install the bracket that is a support for the oil filter tube and the oil level gauge group. Install the oil filter tube and the oil level gauge group.
Typical Example10. Install eight bolts (13) that fasten the pipe to elbow (14). Install the elbow in the turbocharger.11. Install the four bolts that fasten the elbow to aftercooler cover (12).12. Fill the engine with coolant to the correct level. See the Operation & Maintenance Manual.