Information injection-pump assembly
ZEXEL
106673-7484
1066737484
Rating:
Service parts 106673-7484 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME151161
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
106673-7484
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106673-7484
1066737484
Zexel num
Bosch num
Firm num
Name
106673-7484
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.6
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
172
167.7
176.3
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
410
410
410
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(13.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
172
170
174
Basic
*
Fixing the lever
*
Boost pressure
kPa
38
38
Boost pressure
mmHg
285
285
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+0.95
)+0.05-0
.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
154
150
158
Fixing the lever
*
Boost pressure
kPa
38
38
Boost pressure
mmHg
285
285
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-1.05
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
168
162
174
Fixing the lever
*
Boost pressure
kPa
38
38
Boost pressure
mmHg
285
285
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-2.3
Boost pressure
kPa
13.3
12
14.6
Boost pressure
mmHg
100
90
110
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1-1.
3)
Boost pressure
kPa
24.7
24.7
24.7
Boost pressure
mmHg
185
185
185
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
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.
2
1.5
2.5
Remarks
Finish
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=AE83 BCL=2.3+-0.1mm
----------
----------
T1=AE83 BCL=2.3+-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=2deg+-5deg b=37deg+-3deg
----------
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 (Rack position corresponding to 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)
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
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=10deg
----------
a=(2deg)
----------
aa=10deg
----------
a=(2deg)
Information:
Do not put oil on the bearings until the bearing clearance has been checked.1. Install bearings (1) in the connecting rods they were removed from. Make sure the tab in each bearing is in alignment with the notch in each connecting rod.2. Install bearings (2) in the cylinder block. Make sure the tab in each bearing is in alignment with the notch in the cylinder block. 3. Install pin (3) in the end of the crankshaft. Install the pin so that it extends a maximum of 6.4 mm (.252 in) above the surface. 4. Install the dowel in the crankshaft that puts gear (4) in the correct position. Install the dowel so that it extends 4.1 0.5 mm (.161 .020 in) above the surface of the crankshaft.5. Heat gear (4) to a maximum temperature of 233° C (451° F). Gear (4) must be installed on the crankshaft with the "V" timing mark toward the outside.6. Install gear (4) on the crankshaft. Make sure the notch in the gear is in alignment with the dowel on the crankshaft. The dimension from the rear face of the gear to the front face of the crankshaft must be 45.54 0.25 mm (1.793 .010 in). 7. Fasten Tooling (A) and a hoist to the crankshaft (5) as shown. Install the crankshaft in the engine. The weight of the crankshaft is approximately 131 kg (290 lb). 8. Make sure that "V" mark (6) on the crankshaft is in alignment with "V" mark (7) on the idler gear. The side of each thrust plate (8) with the words "BLOCK SIDE" must be installed with this side toward the cylinder block.9. Put clean oil on thrust plates (8). Install thrust plates (8) next to the center main bearings. Do not put oil on bearings (9) until the bearing clearances have been checked.10. Put bearings (9) in their original position in crankshaft main bearing caps (10).11. Check the crankshaft main bearing clearance with Plastigage as follows:a. Put a piece of Plastigage between the crankshaft bearing journal surface and bearing (9).b. Install the crankshaft main bearing caps (10) with the arrow on each cap toward the front of cylinder block. Each crankshaft main bearing cap has a number on the bottom surface and must be installed in the same position as the correct number on the left side of the cylinder block.c. Put 2P-2506 Thread Lubricant on the threads of the cap bolts. Install the cap bolts finger tight.d. Tighten the bolts on the tab end of the caps first to a torque of 258 14 N m (190 10 lb ft).e. Tighten the bolts on the other end of the caps to a torque of 258 14 N m (190 10 lb ft).
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
f. Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end of the cap
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
f. Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end of the cap
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106673-7484
INJECTION-PUMP ASSEMBLY