106682-9290 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066829290

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106682-9290 1066829290

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Service parts 106682-9290 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2310

3. GOVERNOR 105447-1610

4. SUPPLY PUMP 105237-1541

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4143

11. Nozzle and Holder 6162-13-3702

12. Open Pre:MPa(Kqf/cm2) 26.0{265}

13. NOZZLE-HOLDER 105041-7102

14. NOZZLE 105015-6700

15. NOZZLE SET

Include in #1:

106682-9290 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106682-9290 1066829290

Zexel num

Bosch num

Firm num

Name

106682-9290

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 131424-7120

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 3.2 3.15 3.25

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 16.6

Pump speed r/min 875 875 875

Average injection quantity mm3/st. 425 421 429

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

Injection quantity adjustment_02

Adjusting point B

Rack position 6.9+-0.5

Pump speed r/min 335 335 335

Average injection quantity mm3/st. 21 16 26

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 410 410 430

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 14.6

Boost pressure kPa 9.3 6.6 12

Boost pressure mmHg 70 50 90

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 17.8

Boost pressure kPa 44 37.3 50.7

Boost pressure mmHg 330 280 380

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
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K=21 BCL=3.2+-0.1mm N1=875r/min N2=650r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=52deg+-5deg b=(24deg)+-5deg c=(15deg)+-5deg

0000001501 LEVER

1. Adjustment of the control lever (1)Perform idling with the speed lever (a) contacting the pushrod (b) At this time, confirm that the spring (c) is not compressed by speed lever (a)'s operating torque. (2)To set the stop position, compress spring (c) using the speed lever (a) and adjust the rack so that it contacts the guide screw at position L1. Then, set and fix using the lock nut (e). Adjust rack position at this time using shim (f). (3)After pulling the speed lever (a) in the stop direction and releasing it, confirm that it returns to the idle position.
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L1=0.2~2mm
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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)- (4)-
----------

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

Information:

Start By:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
a. remove crankshaft rear seal and wear sleeve1. Loosen the bolts that hold the oil pan and oil plan plate to the cylinder block. Remove the bolts that hold the oil pan plate to the flywheel housing.2. Install spacers between the oil pan plate and the cylinder block to hold the oil pan plate away from the flywheel housing. 3. Remove turbocharger oil drain tube (1).4. Remove the bolt to clip (3).5. Install tool (A) and fasten a hoist as shown. Remove bolts (4) and remove flywheel housing (2). The weight of the flywheel housing is 39 kg (85 lb.). The following steps are for the installation of the flywheel housing.6. Clean the old gasket from the surfaces of the cylinder block and flywheel housing that make contact with each other. Install a new gasket on the cylinder block.7. Install two 1/2" - 13 NC guide bolts in the cylinder block. Install tool (A) on the flywheel housing. Fasten a hoist and put the flywheel housing in position on the guide bolts. Install all but two bolts in the flywheel housing. Remove tool (A) and the guide bolts. Install the other two bolts. Tighten the flywheel housing bolts in the sequence as shown. 8. Cut the bottom of the gasket even with the flywheel housing and cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan plate. Remove shims from each side of the engine. Tighten all of the oil pan bolts. Install the bolts that hold the oil pan plate to the flywheel housing.9. Install the bolt to clip (3). Install turbocharger oil drain tube (1).End By:a. install crankshaft rear seal and wear sleeve