106682-9210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066829210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106682-9210 1066829210

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Cross reference number

ZEXEL 106682-9210 1066829210

Zexel num

Bosch num

Firm num

Name

106682-9210

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 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 14.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 331 328 334

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

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

Injection quantity adjustment_02

Adjusting point B

Rack position 7.7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 19 17.5 20.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT for 106684-4190; RAL (3)Rack difference between N = N1 and N = N2 (4)Idle sub spring setting: L1.
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K=14 RAL=15.7+0.2mm N1=900r/min N2=700r/min L1=7.8-0.5mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(21deg)+-5deg b=(21deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb
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aa=0r/min bb=1-0.5mm
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a=(73deg) b=43.5deg+-5deg

Timing setting

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

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

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the bolts holding gasket assemblies (1) and (2) to the cylinder head. 2. Disconnect six fuel injection line nuts (3).
Do not allow the tops of nozzles (4) to turn while the fuel lines are loosened. The nozzles will be damaged if the top of the nozzle turns in the body. Defective fuel nozzles will damage the engine due to incorrect spray patterns.
3. Hold the tops on the fuel nozzles (4) with a wrench and loosen the fuel line nuts at the nozzles.4. Disconnect the fuel injection line nuts at the nozzles and remove the fuel injection lines.5. Install caps and plugs on the nozzles, fuel lines and in the fuel injection pump to keep dirt from contaminating the fuel system. The following steps are for installation.
Do not let the tops of nozzles (4) turn while the fuel lines are tightened. The nozzles will be damaged if the top of the nozzle turns in the body. Defective fuel nozzles will damage the engine due to improper spray patterns.
6. Remove protection covers from the fuel line connections. Place the fuel injection lines in position and install the fuel injection line nuts finger tight. 7. While holding the tops of fuel nozzles (4), use tool (A) and tighten the fuel injection line nuts to a torque of 40 7 N m (30 5 lb ft).8. Tighten the six fuel injection line nuts (3) at the fuel injection pumps to a torque of 40 7 N m (30 5 lb ft).9. Install the bolts that hold brackets (1) and (2) to the cylinder head. Remove the air from the fuel lines*. See the topic, Priming The Fuel System, in the Maintenance Manual.