106673-7460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737460

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7460 1066737460

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Cross reference number

ZEXEL 106673-7460 1066737460

Zexel num

Bosch num

Firm num

Name

106673-7460

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. 161.5 157.5 165.5

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 430 430 430

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(13.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 161.5 160.5 162.5

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+1.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 154 150 158

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. 156 150 162

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 R2-1.65

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. 6]

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=AD81 BCL=1.65+-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.
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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

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=2deg+-5deg b=37deg+-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 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
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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(13.4)+1.1mm
----------

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=5deg
----------
a=(2deg)

Information:

Start By:a. remove automatic timing advanceb. remove oil panc. remove water pumpd. remove crankshaft front seal and wear sleeve 1. Disconnect clip (1) for the wiring harness.2. Remove connector (2) from the clip. 3. Fasten Tooling (A) and a hoist to the timing gear cover. The weight of the timing gear cover is 18 kg (40 lb).4. Use Tooling (B) to remove studs (3).5. Move fuel overflow tube (4) out of the way.6. Remove cover (5) and the gasket.7. Disconnect all wiring harness clips from the timing gear housing, and move the wiring harness out of the way.8. Remove the bolts that hold the timing gear cover to the cylinder block, and remove the timing gear cover.9. Remove the gasket for the timing gear cover.10. Thoroughly clean the gasket surface of the cylinder block and the timing gear cover. Be careful not to scratch or mar the gasket surface of the aluminum timing gear cover.Install Timing Gear Cover
1. Install new O-ring seal (1) on the fuel injection pump housing. Put clean engine oil on the O-ring seal.2. Put new gasket (2) in position on the cylinder block. Engage the gasket with the two dowels. Use clean 2S-3230 Bearing Lubricant to hold the gasket in place on the cylinder block. 3. Put the timing gear cover in position on the dowels. Install the bolts that hold the timing gear cover to the cylinder block.4. Install cover (6), and a new gasket.5. Connect the wiring harness clips to the timing gear housing.6. Connect the clip that holds fuel overflow tube (5).7. Use Tooling (B) to install studs (3).8. Remove Tooling (A).9. Put 5P-3413 Pipe Sealant with "Teflon" on the threads of stud (4). Use Tool (B) to install stud (4) to a height of 28.96 mm (1.140 in).10. Install the clip that holds the wiring harness.11. Install the connector in the clip.12. Trim gasket (2) even with the oil pan surface of the cylinder block and timing gear cover.End By:a. install crankshaft front seal and wear sleeveb. install water pumpc. install oil pand. install automatic timing advance