106685-4251 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066854251

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106685-4251 1066854251

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Cross reference number

ZEXEL 106685-4251 1066854251

Zexel num

Bosch num

Firm num

Name

106685-4251

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 131425-2120

Overflow valve opening pressure kPa 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 3.3 3.25 3.35

Rack position R=10++

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 12.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 404 399 409

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 131 131

Boost pressure mmHg 980 980

Injection quantity adjustment_02

Adjusting point B

Rack position 6.7+-0.5

Pump speed r/min 280 280 280

Average injection quantity mm3/st. 28.5 26.5 30.5

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 C

Rack position R1(8.4)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 185.5 182.5 188.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1(8.4)

Boost pressure kPa 30.7 28 33.4

Boost pressure mmHg 230 210 250

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1+3.9

Boost pressure kPa 117 110.3 123.7

Boost pressure mmHg 880 830 930

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 stroke: BCL (4)Set using full load screw at shipping. (5)Stop lever at stopping (with the stop lever at full)
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K=13 BCL=3.9+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=4deg+-5deg b=37deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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a=19deg+-5deg b=53deg+-5deg

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)At rack position = bb or more
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aa=25deg bb=10mm
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a=(150deg)

Information:

Guidelines For Reusable Parts; Valves And Valve Springs, Forms SEBF8002 and SEBF8034 have the procedure and specifications necessary for checking used valves and valve springs.(1) Springs (Inner And Outer):Inner Valve Spring (4W2472): Assembled length ... 50.24 mm (1.978 in)Load at assembled length ... 178 18 N (40.1 4.1 lb)Operating length (min) ... 35.97 mm (1.416 in)Load at min operating length ... 343 17 N (77.2 3.8 lb)Free length after test ... 65.7 mm (2.60 in)Outside diameter ... 25.13 mm (.989 in)Outer Valve Spring (4W2471): Assembled length ... 53.24 mm (2.096 in)Load at assembled length ... 245 24 N (55.1 5.4 lb)Operating length (min) ... 38.96 mm (1.534 in) Load at min operating length ... 805 40 N (181.1 9.0 lb)Free length after test ... 59.5 mm (2.34 in)Outside diameter ... 37.31 mm (1.469 in) The following springs (inner and outer) are used on the exhaust valves with the 70 PSI Williams Blue-Ox Exhaust Brake.Inner Valve Spring (9Y3327): Assembled length ... 50.24 mm (1.978 in)Load at assembled length ... 264 26 N (59.4 5.9 lb)Operating length (min) ... 36.14 mm (1.423 in)Load at min operating length ... 445 22 N (100.1 5.0 lb)Free length after test ... 70.9 mm (2.79 in)Outside diameter ... 29.83 mm (1.174 in)Outer Valve Spring (9Y3326): Assembled length ... 53.24 mm (2.096 in)Load at assembled length ... 521 52 N (117.2 11.7 lb)Operating length (min) ... 38.96 mm (1.534 in)Load at min operating length ... 992 50 N (223.2 11.3 lb)Free length after test ... 69.04 mm (2.718 in)Outside diameter ... 42.61 mm (1.678 in)(2) Height to top of valve guide ... 32.3 0.8 mm (1.27 .03 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Coat the intake and exhaust valve stems with 8T2998 Camshaft Lubricant prior to installation in the cylinder head.Use again minimum:1W3860 Exhaust ... 9.408 mm (.3704 in)2W2622 Intake ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head (new) ... 9.487