106673-7462 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066737462

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106673-7462 1066737462

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Cross reference number

ZEXEL 106673-7462 1066737462

Zexel num

Bosch num

Firm num

Name

106673-7462

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 13.7

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 390 390 390

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(13.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 172.5 170.5 174.5

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. 157 153 161

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. 171.5 165.5 177.5

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 R2-1.65

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. 7]

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
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T1=AE17 BCL=1.65+-0.1mm
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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.
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L=1-0.2(mm) 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.
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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
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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
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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)
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N1=1100r/min Ra=R1(13.7)+0.9mm
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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
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a=(2deg)

Information:

Start By:a. remove flywheel housing 1. Loosen four bolts (1) approximately 6.4 mm (.25 in). Use Tool (A) to loosen camshaft rear gear (2) from the camshaft.2. Remove Tool (A) and four bolts (1).
If balancer gear (3) is in a position similar to that shown in the picture, the weight on balancer gear (3) will turn down when the camshaft rear gear is removed. To prevent personal injury, hold balancer gear (3) when camshaft rear gear (2) is removed.
3. Remove camshaft rear gear (2). 4. Remove bolt (4), plate (5) and balancer gear (3).5. Inspect the bearing in balancer gear (3). The inside diameter (bore) of a new bearing must be 50.853 to 50.950 mm (2.0021 to 2.0059 in). 6. Use Tooling (B) and a press to remove the bearing from balancer gear (3). 7. Inspect shaft (7) for wear or damage. The outside diameter (new) of shaft (7) must be 50.787 to 50.813 mm (1.9995 to 2.0005 in).8. If a replacement of shaft (7) is necessary, remove bolts (6) and shaft (7) from the cylinder block.Install Camshaft Rear Gear & Balancer
1. Install shaft (7) and four bolts (6) on the cylinder block. 2. Use Tooling (A) to install the bearing in balancer gear (3). Install the bearing so that the bearing joint is on the weight side of the gear within 20 degrees of the centerline as shown. Install the bearing so that it is 1.3 mm (.05 in) from the opposite surface on balancer gear (3). 3. Put clean engine oil on the inside diameter of the bearing in the balancer gear. Install balancer gear (3) and plate (5). Make sure the side of the balancer gear with the weight is toward the cylinder block. Install the bolt (4) that holds the balancer gear in position on the shaft. Check to make sure that there is 0.15 to 0.36 mm (.006 to .014 in) end play between the balancer gear and the shaft.
Be sure the timing "V" marks (8) are aligned when the camshaft rear gear is installed on the camshaft.
4. Engage camshaft rear gear (2) with the dowel on the camshaft. Install bolts (1).5. Tighten bolts (1) to a torque of 23 to 31 N m (17 to 23 lb ft).End By:a. install flywheel housing