106681-4090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066814090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106681-4090 1066814090

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Cross reference number

ZEXEL 106681-4090 1066814090

Zexel num

Bosch num

Firm num

Name

106681-4090

INJECTION-PUMP ASSEMBLY
SA12V140

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000

Overflow valve 131425-1620

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.5 3.45 3.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 14.8

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 340.6 338.6 342.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Remarks
Standard point A's rack position same as row R

Injection quantity adjustment_02

Adjusting point -

Rack position 9.5+-0.5

Pump speed r/min 340 340 340

Average injection quantity mm3/st. 20 18.5 21.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 13.8

Boost pressure kPa 30.7 28 33.4

Boost pressure mmHg 230 210 250

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 15

Boost pressure kPa 53.3 46.6 60

Boost pressure mmHg 400 350 450

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2.5 2 3

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Rack limit for 106689-4030 (row R) ; RAL (4)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2 (5)Set the No 1 idle sub spring. (6)Set the 2nd idle sub spring.
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K=20 RAL=16.5+0.2mm BCL=1.2+-0.1mm N1=1050r/min N2=750r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(18deg)+-5deg b=(26deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
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aa=0r/min bb=1-0.2mm
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a=29deg+-5deg b=(73deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

(1) End play for shaft (new) ... 0.114 0.038 mm (.0045 .0015 in.) Maximum permissible end play (worn) ... 0.20 mm (.008 in.)(2) Tighten band clamps with procedure that follows: a. Tighten to ... 13.6 1.1 N (120 10 lb.in.)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 13.6 1.1 N (120 10 lb.in.)(3) Thickness of thrust bearing ... 5.36 0.03 mm (.211 .001 in.)(4) Diameter of shaft (new) ... 14.254 to 14.262 mm (.5612 to .5615 in.) Bore in the bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in.)Maximum permissible clearance between bearing and shaft (worn) ... 0.08 mm (.003 in.)(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.23 mm (.009 in.)(6) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 to .8767 in.) Outside diameter of the bearing (new) ... 22.144 to 22.154 mm (.8718 to .8722 in.)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in.)(7) Turbocharger impeller installation at room temperature: a. Put 6V1541 Quick Cure Primer on the nut and the shaft threads to clean them, if necessary.b. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
Do not let the retaining compound get into the compressor wheel bore or on the shaft, because it can make removal of the compressor wheel difficult during future turbocharger disassembly.
c. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.d. Tighten the compressor wheel retainer nut to a torque of ... 60 3 N m (44 2 lb.ft.)
Do not bend or add stress to the shaft when the nut is tightened.
(8) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in.)(9) Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) ... 55 5 N m (40 4 lb.ft.)