106873-7163 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068737163

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106873-7163 1068737163

Service parts 106873-7163 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5970

3. GOVERNOR 105923-1163

4. SUPPLY PUMP 105237-4770

5. AUTOM. ADVANCE MECHANIS 105691-3792

6. COUPLING PLATE 105664-2020

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7333

11. Nozzle and Holder ME093528

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

13. NOZZLE-HOLDER 105041-4121

14. NOZZLE

15. NOZZLE SET 105019-0510

Include in #1:

106873-7163 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106873-7163 1068737163

Zexel num

Bosch num

Firm num

Name

106873-7163

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 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)Air cylinder ON (5)Air cylinder OFF (6)Damper spring setting
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T1=AC77 BCL=1.35+-0.1mm
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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.
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L=1-0.2mm N2=800r/min C2=(10)deg 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)When air cylinder OFF. (4)When air cylinder ON. (5)Viewed from feed pump side.
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aa=37.5mm
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a=41deg+-3deg b=13deg+-5deg c=(6deg)

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)
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aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
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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
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N1=325r/min Ra=8.5+-0.1mm
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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)
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N1=1100r/min Ra=R1(13.9)+1.65mm
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0000001701 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)
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L1=(1)++mm L2=(1)++mm P1=0kPa(0kgf/cm2) P2=392+98kpa(4+1kgf/cm2) N1=350r/min R1=8.5+-0.1mm T1=4.9~6.86N-m(0.5~0.7kgf-m)
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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)-
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aa=4deg
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a=(50deg)