106681-4240 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066814240

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106681-4240 1066814240

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Service parts 106681-4240 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2200

3. GOVERNOR 105447-1631

4. SUPPLY PUMP 105237-1690

5. AUTOM. ADVANCE MECHANIS 105682-5010

6. COUPLING PLATE 105664-0670

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6220

11. Nozzle and Holder 35A61-00010

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

13. NOZZLE-HOLDER 105030-4320

14. NOZZLE 105015-8520

15. NOZZLE SET

Include in #1:

106681-4240 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106681-4240 1066814240

Zexel num

Bosch num

Firm num

Name

106681-4240

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

Rack position
Point A R=A

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 14.2

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 447 438 456

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 128 128

Boost pressure mmHg 960 960

Injection quantity adjustment_02

Adjusting point C

Rack position 6.8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 22 19 25

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-3.2

Boost pressure kPa 50.7 48 53.4

Boost pressure mmHg 380 360 400

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(14.2)

Boost pressure kPa 115 108.3 121.7

Boost pressure mmHg 860 810 910

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)Target notch: K (2)Boost compensator stroke: BCL
----------
K=8 BCL=3.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)At the center of the lever key groove
----------

----------
a=27.5deg+-5deg b=37.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-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=(110deg)

Information:

Polarity is negative ground.Rotation can be either direction.Output at 14 V and 2000 rpm (cold) ... 46 AOutput at 14 V and 5000 rpm (cold) ... 58 ARated output (hot) ... 65 AField current at 12 V and 80°F (27°C) ... 4.4 to 4.9 A(1) Four position cap for voltage adjustment.(2) Torque for pulley nut ... 75 5 lb. ft.(100 7 N m)(3) Torque for stud nut for battery connection ... 25 to 40 lb. in.(2.8 to 4.5 N m)5S6698 12V 75A (Delco-Remy Number 1117242)
Polarity is negative ground.Rotation can be either direction.Output at 5000 rpm (cold) ... 70 A *Rated output (hot) ... 75 AField current at 12 V and 80°F (27°C) ... 4.1 to 4.5 A*Fasten carbon pile to battery to get maximum output.(1) Torque for pulley nut ... 75 5 lb. ft.(100 7 N m)(2) Torque for stud nut for battery connection ... 9 to 11 lb. ft.(12 to 15 N m)2P1204 24V 19A (Prestolite Number ANB7002 or ANB7004)*
Polarity is negative ground.Rated output at 28V ... 19 AOutput at 1500 rpm and 28V ... 10 AResistance of the rotor at 77°F (25°C) ... 18 to 20 ohmCurrent consumption (draw) at 77°F (25°C) and 24V ... 1.20 to 1.33 A(1) Torque for nuts holding pulley ... 75 5 lb. ft.(100 7 N m)(2) Torque for nuts for terminals for field and ground ... 25 to 30 lb. in.(2.8 to 3.4 N m)(3) Torque for screws holding terminal plate ... 10 to 15 lb. in.(1.1 to 1.7 N m)(4) Torque for bolts ... 25 to 30 lb. in.(2.8 to 3.4 N m)(5) Torque for bolts holding regulator ... 45 to 50 lb. in.(5.1 to 5.7 N m)(6) Torque for nut for terminal ... 45 to 50 lb. in.(5.1 to 5.7 N m)(7) Torque for nut for positive terminal ... 225 to 250 lb. in.(25.4 to 28.3 N m)2P1699 Regulator (Prestolite Number VSH-6401A)4N5938 Regulator (Prestolite Number VSH-6401B)6N3821 Regulator (Prestolite Number VSH-6401C)*Including: