106681-4222 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066814222

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106681-4222 1066814222

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 106681-4222 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 106681-4222 1066814222

Zexel num

Bosch num

Firm num

Name

106681-4222

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 105780-8130

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 131424-3420

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 2.8 2.75 2.85

Beginning of injection position
Governor 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 11.2

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 303 294 312

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 107 107

Boost pressure mmHg 805 805

Remarks
Injection at all cylinders.

Injection quantity adjustment_02

Adjusting point C

Rack position 5.6+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 26 23 29

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Injection only at cylinders 1, 3, 4 and 6.

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 260 260 280

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-2.5

Boost pressure kPa 55.3 48.6 62

Boost pressure mmHg 415 365 465

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.2)

Boost pressure kPa 98 95.3 100.7

Boost pressure mmHg 735 715 755

Timer adjustment

Pump speed r/min 450--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 400

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)The torque control spring does not operate. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Idle sub spring setting: L1.
----------
K=25 BCL=2.5+-0.1mm L1=5-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(20deg)+-5deg b=(29deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)Seal at delivery.
----------
aa=0r/min bb=3-0.5mm
----------
a=27deg+-5deg b=62.5deg+-5deg

Timing setting

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

----------
a=(20deg)

Information:

start by:a) remove oil pumpb) remove timing gear coverc) remove flywheel housingd) remove pistons For more detail about removal of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS. 1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap. 2. Remove bearing caps No. 2 through No. 4. Remove thrust plates from No. 3 upper bearing.3. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 5 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 270 lb. (122 kg).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with tooling (A).5. Remove dowel and pin from crankshaft with tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface .25 .02 in. (6.4 0.5 mm).2. Install dowel (2) until it is extended from the surface .16 .02 in. (4.1 0.5 mm). 3. Heat crankshaft gear (3) to a maximum temperature of 400°F (204°C). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft.5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Do not cause damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.6. Check the bearing clearances with tool (B).7. Put clean engine oil on the bolts for caps No. 1 and No. 5. Install No. 1 and No. 5 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 3 upper main bearing. Install the thrust plates with the side that has the identification "Block Side" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 4. Install caps No. 2 through No. 4 with the bolts finger tight. Make sure the arrows are toward the front of the block.10. Tighten the cap bolts as follows: a) Tighten the bolts on the tab end of the caps first to a torque of 190 10 lb. ft. (260 14 N m).b) Tighten the bolts on the other end of the caps to a torque of 190 10 lb. ft. (260 14 N m).c) Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end