106873-7251 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068737251

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-7251 1068737251

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Service parts 106873-7251 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-7010

3. GOVERNOR 105923-1421

4. SUPPLY PUMP 105237-4770

5. AUTOM. ADVANCE MECHANIS 105681-1650

6. COUPLING PLATE 105664-2230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7450

11. Nozzle and Holder ME093733

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-4120

14. NOZZLE

15. NOZZLE SET 105019-0620

Include in #1:

106873-7251 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106873-7251 1068737251

Zexel num

Bosch num

Firm num

Name

106873-7251

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 11.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 116 112.5 119.5

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 480 480 480

Each cylinder's injection qty mm3/st. 14 11.9 16.1

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 116 115 117

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 123.5 119.5 127.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.55 )

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 112.5 108.5 116.5

Fixing the lever *

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3 2.5 3.5

Remarks
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)Damper spring setting
----------
T1=AC91
----------

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=32deg+-5deg b=35.5deg+-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 (equivalent to R = dd).
----------
aa=54mm bb=1100r/min cc=3+-0.3mm dd=17.5mm
----------
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=335r/min Ra=7.9+-0.1mm
----------

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=(40deg)

Information:

Keypad
Keypad (6) is used to control the information that is shown on upper display (4) and lower display (5). The seven keys have two sets of functions, normal functions and service functions. For a description of the service functions of the keys; see the topic Service Mode. The normal functions of the keys are: Left Key- This key only functions when the GSC is in service mode. See the topic Service Mode. Phase Select Key- Selects which phase of the generator output is shown on the GSC. Pressing this key allows the operator to check the voltage, current, and frequency of each phase one at a time. Engine Meter Key- Stops the scrolling of engine conditions on lower display (5) and continuously shows the value for one particular engine condition. The pointer flashes to indicate scrolling is stopped. Pressing the key again, resumes the scrolling of engine conditions. Lamp Test Key- Performs a lamp test on the GSC and the optional alarm module. On the GSC the eight fault indicators are ON continuously, every segment of upper display (4) and lower display (5) are ON. On the optional alarm module all of the indicators are ON and the horn sounds. Alarm Codes Key- If the fault alarm indicator (3) is FLASHING, pressing this key causes the upper display (4) to show the corresponding alarm fault code. Pressing this key again, resumes the showing of generator output information on the upper display (4). If the fault alarm indicator (3) is OFF, this key has no function. For more information on alarm fault codes, see the topic Fault Description. Exit Key- This key only functions when the GSC is in service mode. See the topic Service Mode. Service Mode Key- Pressing this key causes the GSC to enter service mode. See the topic Service Mode.Engine Protection Controls
Engine and generator operating conditions and parameters are monitored and displayed on the Generator Set Control (GSC) Panel. The GSC detects faults that are alarm and shutdown conditions.The engine will continue to run when an alarm condition fault is displayed. The engine will automatically shut down if one of the following faults is detected and displayed.* Low oil pressure,* High coolant temperature,* Engine overspeed,* Low coolant level (if provided),* Engine overcrank.The activation of the Emergency Stop Push Button (ESPB) is also provided on the control panel.Fault Indicators
The eight fault indicators, located on the front of the GSC, are used to show and describe a fault that is present. * The yellow fault alarm indicator flashes when the GSC detects a fault that is an alarm condition. The engine continues to run and start. The fault alarm indicator is accompanied by an alarm fault code that is shown on the upper display when the Alarm Codes Key is pressed. Refer to Service Manual SENR5827 for fault code descriptions. * A red fault shutdown indicator flashes when the GSC detects a fault that is a shutdown condition. The engine is shutdown if it is running