106689-4050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066894050

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106689-4050 1066894050

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Cross reference number

ZEXEL 106689-4050 1066894050

Zexel num

Bosch num

Firm num

Name

106689-4050

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 131424-3420

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 2.8 2.75 2.85

Rack position
Point A R=A

Beginning of injection position
Opposite to the driving 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 14.5

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 491 482 500

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 7+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 24.5 21.5 27.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 450--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 400

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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a=(20deg)

Information:

Typical Example1. Disconnect wire (1) from Jake Brake. Remove three bolts (2) and remove the Jake Brake.
Typical Example2. Remove Jake Brake exhaust bridge assemblies (3). The following steps are for the installation of the Jake Brake.3. Install Jake Brake exhaust bridge assemblies (3) in the same orientation as illustrated.4. Position Jake Brake assembly and install bolts (2). Connect wire (1).End By:a. install valve cover assemblies as they are illustrated.Disassemble & Assemble Jake Brake
Remove the control valve and slave piston carefully. Control valves are under load from the control valve springs. The slave piston is retained by springs that are under heavy compression. Remove with care to avoid injury.
Start By:a. remove Jake Brake 1. Apply finger pressure to the control valve cover (2). Rotate retaining ring (1) to the slot in the housing. Remove the retaining ring. Release finger pressure slowly. Remove insert (3), spring (4), spring (5), collar (6) and control valve (7).2. Remove solenoid valve (8). Remove three O-ring seals (9) from housing.3. Remove locknut (11). Back out adjusting screw (10) until slave piston is fully retracted.4. Clamp and depress retainer (18) until retainer is 1 mm (.030 in) below the retaining ring groove. Remove retaining ring (19). Back out clamp until springs are loose. Remove clamp. Remove retainer (18), spring (17), spring (16) and slave piston (15).5. Remove anti-rotation pin (13) and washer (12). Remove master piston assembly (14).The following steps are for the assembly of the Jake Brake.6. Inspect master piston assembly (14) for damage. The piston surface must be free of score or wear marks. The piston must move freely in the housing bore. Inspect the spring to insure it is not broken.7. Compress the return spring in the master piston assembly with a pick or probe. While compressed, insert a small pin into the access hole and remove pick or probe. Insert the master piston assembly. Install anti-rotation pin (13) and washer (12) into the housing and remove small pin. The return spring will then be retained by the anti-rotation pin.8. Install slave piston (15), spring (16), spring (17), and retainer (18). Clamp and compress the slave piston retainer until retainer is about 1 mm (.030 in) below the retaining ring groove. Install retaining ring (19). Release clamp.9. Screw adjusting screw (12) in until touching slave piston assembly. Install locknut (11).10. Check the O-ring seals for the solenoid valve for wear or damage. Replace as required. Install three O-ring seals (9) on the solenoid valve. Install solenoid valve (8). Tighten the solenoid to a torque of 7 N m (60 lb in). Be sure O-ring seals are seated properly. Be careful not to twist or unseat O-ring seals while installing.11. Install control valve (7). Install collar (6) with longer sleeve area up. Install spring (4), spring (5), retainer (3) and control valve cover (2). Depress control valve cover with finger. Install retaining ring (1). Rotate retaining ring so the retaining ring ears are located away from the slot in the housing. Release finger