Information injection-pump assembly
ZEXEL
106873-7450
1068737450
Rating:
Service parts 106873-7450 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME161933
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/24.5{250}
14.
NOZZLE
Include in #1:
106873-7450
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106873-7450
1068737450
Zexel num
Bosch num
Firm num
Name
106873-7450
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
12.6
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
142
137.7
146.3
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
445
445
445
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
142
141
143
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.05
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
140
136
144
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.8)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
138
134
142
Fixing the lever
*
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=AC95
----------
----------
T1=AC95
----------
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=30deg+-5deg b=35deg+-3deg
----------
aa=37.5mm
----------
a=30deg+-5deg b=35deg+-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 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(12.6)+1.05mm
----------
----------
N1=1100r/min Ra=R1(12.6)+1.05mm
----------
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=6deg
----------
a=(50deg)
----------
aa=6deg
----------
a=(50deg)
Information:
Inspect/Replace
Alternator and Fan Drive Belts
Inspect the condition and adjustment of alternator and accessory drive belts. Examine all drive belts for wear and replace if they show any signs of wear. Loose or worn pulley grooves cause belt slippage and low accessory drive speed. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys and possibly slip enough to cause overheating.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.Adjust
1. Remove belt guard. Inspect the condition and adjustment of alternator belts and accessory drive belts, if equipped.2. To check the belt tension, apply 110 Newton (25 lb) force, perpendicular to the belt, midway between the driving and driven pulley. Measure the belt deflection. Correctly adjusted belts will deflect 15 to 20 mm (9/16 to 7/8 inch).If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, do not install the belt guard. Perform the following procedure to adjust the belt tension.
(1) Typical belt assembly mounting bolt(2) adjusting nut3. Loosen the mounting bolt (1).4. Loosen the bracket adjusting nut(s) (2).5. Tighten or loosen the bracket adjusting nut(s) to obtain the correct adjustment.6. Tighten nuts (1) and (2).7. Check the belt tension. If the belt tension requires further adjustment, repeat steps 3 through 6.8. Install the belt guard.If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.Hoses and Clamps
* Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are cracked or soft and tighten loose clamps.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Check for the following:* End fittings damaged, leaking or displaced.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on
Alternator and Fan Drive Belts
Inspect the condition and adjustment of alternator and accessory drive belts. Examine all drive belts for wear and replace if they show any signs of wear. Loose or worn pulley grooves cause belt slippage and low accessory drive speed. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys and possibly slip enough to cause overheating.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.Adjust
1. Remove belt guard. Inspect the condition and adjustment of alternator belts and accessory drive belts, if equipped.2. To check the belt tension, apply 110 Newton (25 lb) force, perpendicular to the belt, midway between the driving and driven pulley. Measure the belt deflection. Correctly adjusted belts will deflect 15 to 20 mm (9/16 to 7/8 inch).If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, do not install the belt guard. Perform the following procedure to adjust the belt tension.
(1) Typical belt assembly mounting bolt(2) adjusting nut3. Loosen the mounting bolt (1).4. Loosen the bracket adjusting nut(s) (2).5. Tighten or loosen the bracket adjusting nut(s) to obtain the correct adjustment.6. Tighten nuts (1) and (2).7. Check the belt tension. If the belt tension requires further adjustment, repeat steps 3 through 6.8. Install the belt guard.If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.Hoses and Clamps
* Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are cracked or soft and tighten loose clamps.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Check for the following:* End fittings damaged, leaking or displaced.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on
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Mitsubishi
Mitsubishi
Mitsubishi
106873-7450
INJECTION-PUMP ASSEMBLY