106682-4490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066824490


 

Information injection-pump assembly

ZEXEL 106682-4490 1066824490
106682-4490 INJECTION-PUMP ASSEMBLY
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Service parts 106682-4490 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106068-2100
3. GOVERNOR 105447-5700
4. SUPPLY PUMP 105237-1750
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-0600
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5980
11. Nozzle and Holder 74W 3227 1A
12. Open Pre:MPa(Kqf/cm2) 31.4{320}
13. NOZZLE-HOLDER 105030-3260
14. NOZZLE 105015-7870
15. NOZZLE SET

Include in #1:

106682-4490 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106682-4490 1066824490


Zexel num
Bosch num
Firm num
Name
106682-4490 
 
   
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   8-3-600
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.5 3.45 3.55
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   14.4
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   330 325 335
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   8.8+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   30 27 33
Max. variation between cylinders %   0 -10 10
Fixing the rack   *

Test data Ex:

Governor adjustment

Test data 106682-4490
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL (4)Idle sub spring setting: L1.
----------
K=15 RAL=16.4+0.2mm L1=7.6-0.5mm
----------

Speed control lever angle

Test data 106682-4490
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=11deg+-5deg b=27deg+-5deg

Stop lever angle

Test data 106682-4490
N:Pump normal S:Stop the pump. (1)Normal (2)Use the hole at R = aa
----------
aa=17mm
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

Test data 106682-4490
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(6deg)




Information:


Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
The fuel injection pump housing and governor has been removed from the engine for illustration purposes. 1. Remove flange (1) and the flange assembly from the cover.2. Remove cover (2) from the pump housing. 3. Remove the bypass valve (3) and springs from the pump housing.4. Install tooling (A) on the fuel injection pump and loosen the bushing from the pump housing. Do not loosen screws (4) that hold the levers to the shaft when the pumps are removed or installed. If the levers are moved, fuel pump calibration will be changed. 5. Remove the fuel injection pump (5) from the pump housing. The sleeve on the plunger will slide off the lever as the pump is removed.6. Do Steps 4 and 5 for the remainder of the pumps.Install Fuel Injection Pumps
1. Turn the camshaft until the lifter for the pump to be installed is at its lowest position.2. Install the fuel injection pump (1) in the bore of the pump housing. 3. The sleeve (2) will be engaged with the lever when the pump is installed correctly.
If the levers have been moved on the shaft, fuel pump calibration must be made. (See TESTING AND ADJUSTING).
4. Tighten the bushing with tooling (A) to a torque of 80 7 N m (60 5 lb.ft.).5. Do Steps 1 through 4 for the remainder of the pumps. 6. Install the bypass valve and spring (3) in the pump housing.7. Install the cover (5) on the pump housing. Be sure the spring (3) is in the bore in the cover. 8. Install the flange (4) and the flange assembly on the cover.Disassemble Fuel Injection Pumps
1. Remove bushing (1) and O-ring seal (7) from bonnet (2).2. Remove ring (3) from the bonnet and barrel (4). 3. Remove check valve assembly (9) and spring (8) from the bonnet.4. Remove spring (10) and retainer washer (5).
Keep the plunger and sleeve with their respective barrel for installation. Do not use plungers, sleeves and barrels with other plungers, sleeves and barrels.
5. Remove plunger (11) and sleeve (6).Assemble Fuel Injection Pumps
1. Install the sleeve (4), plunger (5), spring (2) and washer (3) on barrel (1).
Be sure the sleeve and plunger are installed in their original barrel and the large hole in the plunger is up. The sleeve must be installed with the thin flange up.
2. Install the check valve assembly and spring in the bonnet. Connect the barrel and bonnet with the ring. Install the seal and bushing on the bonnet. end by:a) install fuel injection pumps

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