106685-4400 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066854400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106685-4400 1066854400

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Cross reference number

ZEXEL 106685-4400 1066854400

Zexel num

Bosch num

Firm num

Name

106685-4400

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 2.95 3.05

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 13.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 409 404 414

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

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

Injection quantity adjustment_02

Adjusting point C

Rack position 7.2+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 20 18.5 21.5

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT for 106684-4253 (4)Idle sub spring setting: L1. (5)Stop lever at stopping (with the speed lever at full)
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K=22 L1=7.2-0.5mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
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aa=900r/min bb=750r/min
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a=8deg+-5deg b=29deg+-5deg c=10deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
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a=26.5deg+-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)-
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aa=20deg
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a=(30deg)

Information:

3. Loosen the clamps on breather tube (1), and pull it back for clearance. Loosen the clamps on hose (3). Slide hose (3) off of the water pump cover.4. Remove two bolts and remove elbow (2). 5. Remove bolt (4) from the cover on the side of the cylinder block. 6. Remove the three bolts that hold cover (5) to the water pump. Remove cover (5) from the water pump. 7. Remove the two bolts, and remove elbow (7) from bonnet (6). Remove the two bolts, and remove bonnet (6) from the water pump. It is not necessary to remove bolts (10). These bolts only hold the cover to the timing gear cover.8. Remove six long bolts (9) that hold the water pump to the timing gear cover. Remove water pump (8). The following steps are for the installation of the water pump.9. Check the O-ring seals and gaskets, and make replacements if needed. 10. Make sure O-ring seal (11) is in position on the water pump. Put water pump (8) into position in the timing gear cover. Install the bolts that hold the water pump in place.11. Make sure the gaskets are in place. Connect bonnet (6) to the water pump. Connect elbow (7) to the bonnet. 12. Make sure O-ring seal (12) is in position, and install cover (5) on the water pump.13. Install bolt (4) on the cover on the side of the engine.14. Put breather tube (1) in position, and install the clamps that hold it.15. Install the alternator mounting group and alternator on the engine if so equipped. 16. Install the gasket and O-ring seal on elbow (2). Lubricate the O-ring seal with clean oil. Install elbow (2)in the bore of the water pump. Use two bolts to fasten the elbow to the cylinder head.17. Slide hose (3) into position on the water pump. Tighten the hose clamp.18. Fill the cooling system to the correct level. See the Maintenance Manual.Disassemble And Assemble Water Pump
Start By:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing. 1. Remove O-ring seal (3) from adapter (4). Remove the adapter from housing (7). Remove the O-ring seal from the outside of the adapter.2. Remove bolt (1) and washer (2). Use tooling (A) to remove impeller (6) from shaft (13).3. Remove spring and seal (5) from the shaft.4. Remove four bolts (16) from retainer (12) that hold the shaft assembly to the pump housing. Remove O-ring seal (18) from housing (7).5. Remove gear and shaft assembly (17) from the housing. Remove bolt (15), retainer (14), and retainer (12) from