106873-7131 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068737131


 

Information injection-pump assembly

ZEXEL 106873-7131 1068737131
106873-7131 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 106873-7131 1068737131


Zexel num
Bosch num
Firm num
Name
106873-7131 
 
   
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   1-2-7-3- 4-5-6-8
Pre-stroke mm   3.9 3.85 3.95
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   45 44.5 45.5
Difference between angles 2
Cal 1-7
deg.   90 89.5 90.5
Difference between angles 3
Cal 1-3
deg.   135 134.5 135.5
Difference between angles 4
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 5
Cal 1-5
deg.   225 224.5 225.5
Difference between angles 6
Cal 1-6
deg.   270 269.5 270.5
Difference between angles 7
Cal 1-8
deg.   315 314.5 315.5
Injection quantity adjustment
Adjusting point   -
Rack position   12.8
Pump speed r/min   650 650 650
Each cylinder's injection qty mm3/st.   148 143.6 152.4
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8.5+-0.5
Pump speed r/min   400 400 400
Each cylinder's injection qty mm3/st.   23 19.5 26.5
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.8)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   148 147 149
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.15
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   145 141 149
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 106873-7131
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Air cylinder OFF (4)Air cylinder ON (5)Damper spring setting
----------
T1=AC39
----------

Timer adjustment

Test data 106873-7131
(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.
----------
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

Test data 106873-7131
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)When air cylinder OFF. (4)When air cylinder ON. (5)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=(10deg) b=35deg+-3deg c=30deg+-5deg

Stop lever angle

Test data 106873-7131
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)

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=8.5+-0.1mm
----------

0000001601 RACK SENSOR

Test data 106873-7131
(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(12.8)+1.15mm
----------

0000001701 AIR CYLINDER

Test data 106873-7131
(A) stopper bolt (B) stopper bolt (a) lever (b) air cylinder (c) speed lever (d) Nut (e) nut 1. Stopper bolt A adjusting method (1)When the air cylinder pressure is P1, confirm that there is a clearance between the stopper bolt (A) and the lever (a). (2)Then, screw in the stopper bolt A and temporarily set where it contacts the stop lever a. (3)Apply P2 to the air cylinder. (4)Confirm that the speed lever (c) operates between idling and full speed positions. (5)Fix the stopper bolt A using nut d. 2. Stopper bolt <B> adjustment method. (1)At air cylinder pressure P1, pump speed N1 and rack position is Ra, adjust stopper bolt (B) so that the speed lever (c) is in the stop position. (2)Move the lever a several times and then fix the stopper bolt B using the nut e. (3)Nut d tightening torque: T1 (4)Nut e tightening torque: T2
----------
P1=0kPa(0kgf/cm2) P2=392+98kPa(4+1kgf/cm2) N1=350r/min Ra=8.5+-0.1mm T1=4.9~7N-m(0.5~0.7kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m)
----------

Timing setting

Test data 106873-7131
(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=6deg
----------
a=(50deg)




Information:

Engine Description
Older 3408 and 3412 models may by precombustion chamber (PC) type engines. Newer 3408 and 3412 models are direct injection (DI) engines.A mechanical governor controls the fuel injection pump output to maintain the engine rpm selected by the operator. The fuel injection pump meters and pumps fuel under high pressure to a fuel injection nozzle for each cylinder. An automatic timing device advances or retards fuel injection to provide the best fuel injection timing over the full range of engine speed.The air/fuel ratio control, located on the governor, restricts the movement of the fuel rack, allowing only the proper amount of fuel to be injected into the cylinders during acceleration, to minimize exhaust smoke.These engines are available as turbocharged (T) or turbocharged and aftercooled (TA). Inlet air is filtered by an air cleaner before entering the engine cylinders. In turbocharged engines, the filtered inlet air is compressed by a turbocharger before entering the engine cylinders. The turbocharger is driven by the engine exhaust.There are four in-head valves (two inlet valves and two exhaust valves) for each cylinder. The camshaft actuates the rocker arms and the valves through mechanical lifters and push rods.The jacket water cooling system uses an expansion tank and a gear driven centrifugal water pump. The engine coolant is circulated by passing through the oil cooler first, then to the engine block and cylinder head. One water temperature regulator for each cylinder bank regulates engine coolant temperature by restricting coolant flow for quick engine warm-up. The regulator opens to allow free circulation of coolant after operating temperature has been reached.The watercooled exhaust manifolds, risers and turbochargers are designed to minimize radiated heat in the engine room.Lubrication of the engine is accomplished by a gear-type pump and bypass valves. The pump provides full pressure lubrication to the engine internal and external parts. The engine lubricating oil (both cooled and filtered) provides unrestricted flow to engine parts when oil viscosity is high or if the oil cooler is restricted or if the oil filter elements become plugged.The engines are available with SAE standard counterclockwise rotation (CCW when viewed from rear of engine). The engines can be equipped with either the SAE No.1 flywheel or the SAE No.0 flywheel to mate with various marine gears. Several marine gear manufacturers offer marine transmissions for the engines through local distributors.Engine Specifications
3408 Engine
3412 Engine

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INJECTION-PUMP ASSEMBLY
106873-7131  
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 611 032 
ME161704 
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8M20
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