Information injection-pump assembly
ZEXEL
106682-9390
1066829390
Rating:
Service parts 106682-9390 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6212-12-3100
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-9390
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-9390
1066829390
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
12
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
363
358
368
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
101
101
Boost pressure
mmHg
760
760
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
365
365
365
Average injection quantity
mm3/st.
8
6.5
9.5
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
D
Rack position
12.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
290
280
300
Basic
*
Fixing the lever
*
Boost pressure
kPa
101
101
Boost pressure
mmHg
760
760
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
(R1)-2.9
Boost pressure
kPa
32
28.7
35.3
Boost pressure
mmHg
240
215
265
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
(R1)-0.9
Boost pressure
kPa
58.7
52
65.4
Boost pressure
mmHg
440
390
490
Boost compensator adjustment_03
Pump speed
r/min
700
700
700
Rack position
R1(12)
Boost pressure
kPa
82.6
82.6
82.6
Boost pressure
mmHg
620
620
620
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)RACK LIMIT: RAL
(5)Boost compensator stroke: BCL
(6)Damper spring setting
----------
RT=1 TH=2.8mm RAL=12.3+-0.1mm BCL=2.9+-0.1mm
----------
----------
RT=1 TH=2.8mm RAL=12.3+-0.1mm BCL=2.9+-0.1mm
----------
Speed control lever angle
F:Full speed
(1)Fix using the stopper bolt.
----------
----------
a=2deg+-5deg
----------
----------
a=2deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=50mm
----------
a=30.5deg+-3deg b=32deg+-5deg
----------
aa=50mm
----------
a=30.5deg+-3deg b=32deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=26mm
----------
a=42.5deg+-5deg b=71deg+-5deg
----------
aa=26mm
----------
a=42.5deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
1. Fasten straps and a hoist to the turbocharger.2. Disconnect tube assemblies (1) and (4) from the turbocharger cartridge assembly.3. Remove four bolts (3) and then remove turbocharger (2). Weight of the turbocharger is 23 kg (51 lb.). The following steps are for the installation of the turbocharger.4. Put turbocharger (2) in position with bolts (3).5. Connect tube assemblies (1) and (4) to the turbocharger cartridge assembly.Disassemble Turbocharger
Start By:a. remove turbocharger 1. Install the turbocharger in tool group (A). Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4).
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
3. Install tool (C) in tool (B), and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6). 4. Put the cartridge assembly in tool (E), and use a press (if necessary) to remove compressor wheel (6) from the turbine wheel and shaft assembly. Do not let the turbine wheel and shaft assembly fall during removal of the compressor wheel from the turbine wheel and shaft. 5. Remove seal ring (7) and shroud (8) from turbine wheel and shaft assembly (9). 6. Bend the tabs of the locks from bolts (10), and remove the bolts and locks.7. Remove backplate assembly (11) from the cartridge housing. 8. Remove spacer (12) from backplate assembly (11). Remove seal rings (13) from spacer (12). 9. Remove collar (14), thrust bearing (15) and O-ring seal (16) from the cartridge housing. 10. Remove top bearing (17) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (17).11. Use tool (F), and remove the two rings that hold the top and bottom bearings in position. Remove the bottom bearings and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.12. Use tool (F), and remove the last ring that holds the bottom bearing in position from the cartridge housing.13. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (18), (21) and (22) must be installed with the round edge of the outside diameter of the rings toward the bearings.
3. Install ring (21) in the cartridge housing with tool (F).4. Install washer (19) and bearing (20) in the cartridge housing. Make sure the short dye mark on bearing (20) is up. 5. Install rings (18) and
Start By:a. remove turbocharger 1. Install the turbocharger in tool group (A). Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4).
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
3. Install tool (C) in tool (B), and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6). 4. Put the cartridge assembly in tool (E), and use a press (if necessary) to remove compressor wheel (6) from the turbine wheel and shaft assembly. Do not let the turbine wheel and shaft assembly fall during removal of the compressor wheel from the turbine wheel and shaft. 5. Remove seal ring (7) and shroud (8) from turbine wheel and shaft assembly (9). 6. Bend the tabs of the locks from bolts (10), and remove the bolts and locks.7. Remove backplate assembly (11) from the cartridge housing. 8. Remove spacer (12) from backplate assembly (11). Remove seal rings (13) from spacer (12). 9. Remove collar (14), thrust bearing (15) and O-ring seal (16) from the cartridge housing. 10. Remove top bearing (17) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (17).11. Use tool (F), and remove the two rings that hold the top and bottom bearings in position. Remove the bottom bearings and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.12. Use tool (F), and remove the last ring that holds the bottom bearing in position from the cartridge housing.13. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (18), (21) and (22) must be installed with the round edge of the outside diameter of the rings toward the bearings.
3. Install ring (21) in the cartridge housing with tool (F).4. Install washer (19) and bearing (20) in the cartridge housing. Make sure the short dye mark on bearing (20) is up. 5. Install rings (18) and