106873-7631 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068737631

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-7631 1068737631

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Service parts 106873-7631 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-7091

3. GOVERNOR 105923-2580

4. SUPPLY PUMP 105237-5020

5. AUTOM. ADVANCE MECHANIS 105691-3990

6. COUPLING PLATE 105664-2020

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7391

11. Nozzle and Holder ME161933

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/24.5{250}

13. NOZZLE-HOLDER 105041-4101

14. NOZZLE

15. NOZZLE SET 105019-0380

Include in #1:

106873-7631 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106873-7631 1068737631

Zexel num

Bosch num

Firm num

Name

106873-7631

INJECTION-PUMP ASSEMBLY
14CD PE8P PE

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 12.7

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 144 139.7 148.3

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(12.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 144 143 145

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 139 135 143

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. 139.5 135.5 143.5

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)Air cylinder ON (4)Air cylinder OFF (5)Damper spring setting
----------
T1=AD95
----------

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

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)When air cylinder ON. (4)When air cylinder OFF. (5)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=(16deg) b=34deg+-3deg c=30deg+-5deg

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)

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(12.7)+0.8mm
----------

0000001601 AIR CYLINDER

<A> stopper bolt <B> stopper bolt <C> stopper bolt (a) lever (b) air cylinder (c) speed lever (d) Nut (e) nut (f) lever (g) nut 1. Stopper bolt <A> adjustment method (1)When air cylinder pressure is P1, set the gap between the lever (a) and the air cylinder (b) to L1. (2)Confirm that the speed lever (c) operates between idling and full speed. (3)Fix stopper bolt <A> using nut (d). 2. Stopper bolt <B> adjustment method. (1)At air cylinder pressure P2, pump speed N1 and rack position is R1, adjust stopper bolt (B) so that the speed lever (c) is in the stop position. (2)Turn the stopper bolt (c) so that the clearance between lever (a) and lever (f) is L2, then fix using nut (g). (3)Move the lever (a) several times and fix stopper bolt <B> using the nut (e). (4)Tightening torque T1 for nuts (d), (e) and (g)
----------
L1=1+0.5++mm L2=0~1.5++mm P1=0kPa(0kgf/cm2) P2=686+98kpa(7+1kgf/cm2) N1=530r/min R1=8.2+-0.1mm T1=4.9~6.86N-m(0.5~0.7kgf-m)
----------

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)

Information:

Introduction
The 6V7020 Nozzle Puller Group can be used as a replacement for the five nozzle puller groups (6V4054, 6V4061, 6V6976, 6V6980 and 6V6981) that are used to remove fuel injection nozzles from the above engines. Some of the parts in the separate tool groups are the same, but in the 6V7020 Nozzle Puller Group only one of each item is included. The 6V7020 Nozzle Puller Group also has several parts and tools that are not in the other five puller groups. See the specific Service Manual nozzle removal procedure. See the information that follows for tool operation.1100, 3100, and 3200 Engine Fuel Injection Nozzles (9L6969, 9L7883, 9L8965, 9L9263, 9N3299, 9N3700, 9N3979, 1W5829)
1. To remove the fuel nozzles from the above engines, disassemble 6V6976 Nozzle Puller Group (1). 2. The tool parts shown above will be needed for nozzle removal.3. Disconnect and remove the rocker shaft, see the Service Manual for procedure. 4. Disconnect fuel line (2) and nozzle fuel line (3), and remove adapter (4) from the cylinder head. Remove bolt (5) and the clamp. 5. Install 6V4151 Leg (6) in the hole with threads where the rocker shaft was fastened. Install 6V4149 Jaw (7) and 6V4152 Screw (8) on fuel nozzle (9). [Jaw (7) will slide into notches in nozzle (9).] 6. Install 6V4150 Leg (10) in 6V4153 Plate (11) and install the plate over leg (6) and screw (8). 7. Install the nut and the washer on screw (8), and using a wrench as shown, remove the nozzle.3300 Engine Fuel Injection Nozzles (7N0449)
1. The tool parts shown above are needed to remove the fuel injection nozzles from this model engine.2. Disconnect the fuel lines and remove the nozzle hold down clamp from both the nozzle to be removed and the nozzle next to it. 3. Install 6V4151 Leg (1) next to the nozzle to be removed. Install 6V4150 Leg (2) in the hole with threads in it by the next nozzle. Put 6V4149 Jaw (3) and 6V4152 Screw (4) on the injector that is to be removed. 4. Put 6V4054 Puller (5) on legs (1) and (2) and install 0S1618 Bolt (6) as shown. Install 1B4206 Nut (7) and 2S5658 Washer on screw (4). Remove the injector.3204 Engine Fuel Injection Nozzles (1W3996)
1. Loosen fuel line (1) and move adapter (2) to get clearance for nozzle removal. Remove bolt (3) and the clamp. 2. Install 6V4152 Screw (4) and 6V6978 Head (5) on the nozzle. Install the remainder of the parts of the nozzle puller group as shown. 3. Be sure 6V6979 Leg (6) is on top of the rocker shaft mount bolt (7). Use a wrench to hold screw (4) so it will not turn while the injector is being removed.3300 Engine Fuel Injection Nozzles (8N7001, 8N7002, 8N7003, 8N7005)
The 6V6980 Nozzle Puller Group is used to remove the fuel injection nozzles for these engines. 1. Disconnect the fuel line and remove the hold down clamp and bolt from the nozzle, but do not remove the nozzle