106682-3040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066823040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106682-3040 1066823040

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Service parts 106682-3040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2941

3. GOVERNOR 105407-7000

4. SUPPLY PUMP 105237-5110

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0970

7. COUPLING PLATE 156639-3420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8311

11. Nozzle and Holder 23600-3140A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-3531

14. NOZZLE

15. NOZZLE SET 105019-2040

Include in #1:

106682-3040 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106682-3040 1066823040

Zexel num

Bosch num

Firm num

Name

106682-3040

INJECTION-PUMP ASSEMBLY
14CA PE6P,6PD PE

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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-4-2-6- 3-5

Pre-stroke mm 3.3 3.27 3.33

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 14.7

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 437 433 441

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 109 109

Boost pressure mmHg 820 820

Injection quantity adjustment_02

Adjusting point B

Rack position R2(10.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 195 192 198

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 6.2+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 11.5 8.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2(10.8)

Boost pressure kPa 25.3 22.6 28

Boost pressure mmHg 190 170 210

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(14.7)

Boost pressure kPa 96 96 96

Boost pressure mmHg 720 720 720

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)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Damper spring setting (5)Boost compensator stroke: BCL
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K=7 L1=16.7+-0.1mm BCL=(3.9)mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(10deg)+-5deg b=(33deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Contacts inner stopper. (2)Contacts outer stopper.
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a=27deg+-5deg b=53deg+-5deg c=(11deg)

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Drive side
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aa=16.7+-0.1mm
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a=(18deg) b=(15deg)

0000001501 Q ADJUSTMENT PIPING

Fuel hose adjusting procedure Fuel inlet hose A Fuel inlet hose B Fuel hose C ( (for bypass) (D) Overflow valve 1. Because the pump gallery is divided into two, be careful of the fuel piping. (1)Connect the fuel inlet hose to port (a). (2)Connect the fuel hose (for bypass) to ports (b) and (c). (3)Assemble the overflow valve (D) to the fuel outlet hose and connect to port (d).
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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)-
----------
aa=20deg
----------
a=(50deg)

Information:

start by:a) remove valve covers and bases Hoods and engine side panels and doors are removed for photo purposes only. 1. Use tool (A) to disconnect the fuel line assemblies from the cylinder head.2. Disconnect fuel line assemblies (1) from the fuel injection valves and remove them from the engine. Install covers on all fuel line connections to keep dirt or foreign material out of the fuel system. 3. Remove nut (2) that holds the fuel injection valve to the adapter assembly. 4. Use tool (B) to remove the fuel injection valves.5. If the fuel injection valves can not be removed with tool (B), use tooling (C). 6. Remove nozzle assembly (3) from body (4).7. Remove seal (5) from the body.Install Fuel Injection Valves
1. Use tool (A) to install seal (2) on valve body (1). 2. Install nozzle assembly (3) on the valve body. Tighten nozzle finger tight only.3. Put a small amount of clean diesel fuel on the seal and install the fuel injection valves in the adapter assemblies.4. Install the nut that holds the fuel injection valves and tighten to a torque of 55 5 lb.ft. (75 7 N m). 5. Remove the covers from the fuel line connections. Put fuel line assemblies (4) in position on the engine. Use tool (B) to tighten the fuel line nuts on the cylinder head adapter assembly. 6. Use tool (C) to tighten fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m).end by:a) install valve covers and bases