Information injection-pump assembly
ZEXEL
106673-7485
1066737485
Rating:
Service parts 106673-7485 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:
106673-7485
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106673-7485
1066737485
Zexel num
Bosch num
Firm num
Name
106673-7485
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
13.3
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
164
159.9
168.1
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(13.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
164
162
166
Basic
*
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
155
151
159
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.8)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
158
152
164
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-2.25
Boost pressure
kPa
10
8.7
11.3
Boost pressure
mmHg
75
65
85
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1-1.
05)
Boost pressure
kPa
22.7
22.7
22.7
Boost pressure
mmHg
170
170
170
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=AF99 BCL=2.25+-0.1mm
----------
----------
T1=AF99 BCL=2.25+-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:
Start By:a. remove flywheel
The crankshaft rear seal and wear sleeve must both be removed because they must be replaced as a new set. The new seal set must not be separated.
1. Use a sharp punch and a hammer to put four equally spaced holes in seal (1).2. Install the tip of Tool (A) into the seal, and use the slide hammer to pull it out of the flywheel housing. Change the location of Tool (A) in the seal in order to pull the seal out evenly. 3. Install two 5/8 "-18 NF × 4 in. (102 mm) long bolts (2) to hold the crankshaft rear gear in position.4. Install 5P-7314 Distorter Ring (3) [part of Tooling (B)] in the space where the seal was removed.
Be careful not to damage the crankshaft rear gear.
5. Use 5P-7312 Distorter Ring (4) [part of Tooling (B)] to distort the wear sleeve. Put the end of the distorter in the space where the seal was removed.6. Turn the distorter to cause distortion to the wear sleeve. Move the distorter to another position, and turn the distorter again. Do this procedure until the wear sleeve is loose on the crankshaft.7. Remove the distorter, distorter ring and wear sleeve.Install Crankshaft Rear Seal & Wear Sleeve
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
1. Fasten Tooling (A) to the crankshaft rear gear.2. Use 6V-1541 Quick Cure Primer to clean the outside diameter of the crankshaft rear gear and inside diameter of the wear sleeve in seal assembly (1).3. Put 9S-3265 Retaining Compound on the outside diameter of the crankshaft rear gear and the inside diameter of the wear sleeve in seal assembly (1).
Do not separate the lip-type seal from the wear sleeve. The material in the large lip of the seal can be damaged easily. A scratch or rub (not visible) from a finger can damage the seal enough that it cannot be used. Install the sleeve in the seal. Once there is separation of the sleeve and lip-type seal they cannot be used again and must be replaced with a new seal group. Do not use any type of lubrication during installation of the seal group. If any type of lubrication is used in the installation of the seal group, early seal failure can result.
4. Put seal group (1) in position on Tooling (A). Be sure direction arrows on the seal are the same as crankshaft rotation. 5. Put clean engine oil on the face of washer on nut (2) [part of Tooling (B)] that contacts the installer.6. Install Tooling (B) onto Tooling (A), and install nut (2) [part of Tooling (B)] on the threaded shaft of Tooling
The crankshaft rear seal and wear sleeve must both be removed because they must be replaced as a new set. The new seal set must not be separated.
1. Use a sharp punch and a hammer to put four equally spaced holes in seal (1).2. Install the tip of Tool (A) into the seal, and use the slide hammer to pull it out of the flywheel housing. Change the location of Tool (A) in the seal in order to pull the seal out evenly. 3. Install two 5/8 "-18 NF × 4 in. (102 mm) long bolts (2) to hold the crankshaft rear gear in position.4. Install 5P-7314 Distorter Ring (3) [part of Tooling (B)] in the space where the seal was removed.
Be careful not to damage the crankshaft rear gear.
5. Use 5P-7312 Distorter Ring (4) [part of Tooling (B)] to distort the wear sleeve. Put the end of the distorter in the space where the seal was removed.6. Turn the distorter to cause distortion to the wear sleeve. Move the distorter to another position, and turn the distorter again. Do this procedure until the wear sleeve is loose on the crankshaft.7. Remove the distorter, distorter ring and wear sleeve.Install Crankshaft Rear Seal & Wear Sleeve
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
1. Fasten Tooling (A) to the crankshaft rear gear.2. Use 6V-1541 Quick Cure Primer to clean the outside diameter of the crankshaft rear gear and inside diameter of the wear sleeve in seal assembly (1).3. Put 9S-3265 Retaining Compound on the outside diameter of the crankshaft rear gear and the inside diameter of the wear sleeve in seal assembly (1).
Do not separate the lip-type seal from the wear sleeve. The material in the large lip of the seal can be damaged easily. A scratch or rub (not visible) from a finger can damage the seal enough that it cannot be used. Install the sleeve in the seal. Once there is separation of the sleeve and lip-type seal they cannot be used again and must be replaced with a new seal group. Do not use any type of lubrication during installation of the seal group. If any type of lubrication is used in the installation of the seal group, early seal failure can result.
4. Put seal group (1) in position on Tooling (A). Be sure direction arrows on the seal are the same as crankshaft rotation. 5. Put clean engine oil on the face of washer on nut (2) [part of Tooling (B)] that contacts the installer.6. Install Tooling (B) onto Tooling (A), and install nut (2) [part of Tooling (B)] on the threaded shaft of Tooling
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106673-7485
INJECTION-PUMP ASSEMBLY