106873-7720 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068737720

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-7720 1068737720

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Cross reference number

ZEXEL 106873-7720 1068737720

Zexel num

Bosch num

Firm num

Name

106873-7720

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 12.7

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)Tolerance for racks not indicated: +-0.05mm. (2)Torque cam stamping: T1 (3)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=(10deg) t1=2.5--sec. t2=2.5--sec.
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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=(37deg)+-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=3.5+-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
----------

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:

Install the new 291-5165 Bellows (10) to tube assembly (2) by placing the end of the bellows with the liner on the flange of the tube assembly. Secure bellows (10) to tube assembly (2) by using one new 202-1838 V Band Clamp (11). Refer to Illustration 7.
Illustration 8 g01794917
(12) 313-9428 Tube As
Install the flanged end of the new 313-9428 Tube As (12) to bellows (10) by using one new V-band clamp (11). Refer to Illustration 8.Note: Make sure that the tube assembly is temporarily supported so that the tube assembly axis lines up with the axis of the bellows before securing the tube assembly to the bellows. That way the weight of the tube is on the support and not on the bellows.
Illustration 9 g01794933
(13) 294-9631 Clamp As (14) 310-7675 Bracket (15) 5P-1076 Hard Washer (16) 8T-4183 Bolt
Install the bottom half of the new 294-9631 Clamp As (13) to the two new 310-7675 Brackets (14) by using two new 5P-1076