Information injection-pump assembly
ZEXEL
106873-7174
1068737174
Rating:
Cross reference number
ZEXEL
106873-7174
1068737174
Zexel num
Bosch num
Firm num
Name
106873-7174
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
1-2-7-3-
4-5-6-8
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
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.9
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
159
154.2
163.8
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
420
420
420
Each cylinder's injection qty
mm3/st.
16
13.6
18.4
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.9)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
159
158
160
Basic
*
Fixing the lever
*
Boost pressure
kPa
28.7
28.7
Boost pressure
mmHg
215
215
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.65
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
166.5
162.5
170.5
Fixing the lever
*
Boost pressure
kPa
28.7
28.7
Boost pressure
mmHg
215
215
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-1.35
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-1.
2)
Boost pressure
kPa
15.3
15.3
15.3
Boost pressure
mmHg
115
115
115
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=AC77 BCL=1.35+-0.1mm
----------
----------
T1=AC77 BCL=1.35+-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.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
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
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=13deg+-5deg b=41deg+-3deg
----------
aa=37.5mm
----------
a=13deg+-5deg b=41deg+-3deg
Stop lever angle
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)
----------
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
----------
----------
N1=325r/min Ra=8.5+-0.1mm
----------
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(13.9)+1.65mm
----------
----------
N1=1100r/min Ra=R1(13.9)+1.65mm
----------
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=4deg
----------
a=(50deg)
----------
aa=4deg
----------
a=(50deg)
Information:
For all marine transmission lubrication and maintenance activities, refer to your marine transmission or vessel OEM literature.Use fuel consumption, service hours, or calendar time, whichever occurs first, to determine maintenance intervals. Experience has shown that maintenance intervals are most accurately scheduled on the basis of fuel consumed rather than service hours.Daily
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner - Check service indicator/Service air cleaner when needed Air Starter (If Equipped) - Check lubricator oil level Clutch (If Equipped) - Check/Adjust/Lubricate Marine Transmission - Check oil levelEvery 2550 L (675 gal) of Fuel or 50 Hours
Zinc Rods - Inspect/ReplaceFirst 12,750 L (3375 gal) of Fuel or 250 Hours
1 Valve Lash - Check/Adjust (at the first oil change interval)Every 12,750 L (3375 gal) of Fuel or 250 Hours or Yearly
1 Scheduled Oil Sampling (S O S) - Obtain Sample and analysis1 Engine Crankcase - Replace oil and filter(s)1 Crankcase Breathers - Clean Fuel System - Clean primary fuel filter (if equipped)/Replace final fuel filter Fuel Tank - Drain water and sediment Cooling System (Conventional HD Coolant Only) - Test for SCA concentration OR obtain Level I coolant analysis/Add SCA if necessary Air Cleaner - Clean/Replace air filter elements Belts - Check/Adjust/Replace Hoses and Clamps - Inspect/Replace Batteries - Clean/Check (if required)Every 51,000 L (13,500 gal) Of Fuel Or 1000 Hours
Engine Protection Devices - Inspect/Check Magnetic Pickup - Inspect/AdjustEvery 153,500 L (40,500 gal) Of Fuel Or 3000 Hours
Water Temperature Regulators (Thermostats) - Replace Cooling System (Extended Life Coolant Only) - Add Extender2 Cooling System (Conventional HD Coolant Only) - Drain/Clean/Replace coolant Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect Valve Lash, Valve Rotators - Check/Adjust Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust PAR Analysis - ObtainEvery 256,000 L (67,500 gal) Of Fuel Or 5000 Hours
Fuel Injection Nozzles - Test/Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Raw/Sea Water Pump - Inspect/Rebuild or Exchange Alternator - Inspect/Rebuild or Exchange Starting Motor - Inspect/Rebuild or Exchange Air Compressor (If Equipped) - Inspect/Rebuild or Exchange Turbocharger - Clean/Inspect/CheckEvery 6000 Hours Or Four Years
Cooling System (Extended Life Coolant Only) - Drain/Flush/Replace CoolantOverhaul
Overhaul Considerations13408 Marine Engines that are equipped with the deep oil sump [87 L (92 qt)] may perform this maintenance after 25,500 L (6750 gal) of fuel or 500 Hours.2If a commercial HD coolant/antifreeze meeting ASTM D4985 specifications is used, or if a mixture of commercial SCA and water is used, this maintenance should be performed at a maximum of One Year.
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner - Check service indicator/Service air cleaner when needed Air Starter (If Equipped) - Check lubricator oil level Clutch (If Equipped) - Check/Adjust/Lubricate Marine Transmission - Check oil levelEvery 2550 L (675 gal) of Fuel or 50 Hours
Zinc Rods - Inspect/ReplaceFirst 12,750 L (3375 gal) of Fuel or 250 Hours
1 Valve Lash - Check/Adjust (at the first oil change interval)Every 12,750 L (3375 gal) of Fuel or 250 Hours or Yearly
1 Scheduled Oil Sampling (S O S) - Obtain Sample and analysis1 Engine Crankcase - Replace oil and filter(s)1 Crankcase Breathers - Clean Fuel System - Clean primary fuel filter (if equipped)/Replace final fuel filter Fuel Tank - Drain water and sediment Cooling System (Conventional HD Coolant Only) - Test for SCA concentration OR obtain Level I coolant analysis/Add SCA if necessary Air Cleaner - Clean/Replace air filter elements Belts - Check/Adjust/Replace Hoses and Clamps - Inspect/Replace Batteries - Clean/Check (if required)Every 51,000 L (13,500 gal) Of Fuel Or 1000 Hours
Engine Protection Devices - Inspect/Check Magnetic Pickup - Inspect/AdjustEvery 153,500 L (40,500 gal) Of Fuel Or 3000 Hours
Water Temperature Regulators (Thermostats) - Replace Cooling System (Extended Life Coolant Only) - Add Extender2 Cooling System (Conventional HD Coolant Only) - Drain/Clean/Replace coolant Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect Valve Lash, Valve Rotators - Check/Adjust Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust PAR Analysis - ObtainEvery 256,000 L (67,500 gal) Of Fuel Or 5000 Hours
Fuel Injection Nozzles - Test/Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Raw/Sea Water Pump - Inspect/Rebuild or Exchange Alternator - Inspect/Rebuild or Exchange Starting Motor - Inspect/Rebuild or Exchange Air Compressor (If Equipped) - Inspect/Rebuild or Exchange Turbocharger - Clean/Inspect/CheckEvery 6000 Hours Or Four Years
Cooling System (Extended Life Coolant Only) - Drain/Flush/Replace CoolantOverhaul
Overhaul Considerations13408 Marine Engines that are equipped with the deep oil sump [87 L (92 qt)] may perform this maintenance after 25,500 L (6750 gal) of fuel or 500 Hours.2If a commercial HD coolant/antifreeze meeting ASTM D4985 specifications is used, or if a mixture of commercial SCA and water is used, this maintenance should be performed at a maximum of One Year.
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106873-7174
INJECTION-PUMP ASSEMBLY