Information injection-pump assembly
ZEXEL
106661-0760
1066610760
NISSAN-DIESEL
1671396516
1671396516
Rating:
Service parts 106661-0760 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96505
12.
Open Pre:MPa(Kqf/cm2)
22.6{230}
15.
NOZZLE SET
Include in #1:
106661-0760
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106661-0760
1066610760
NISSAN-DIESEL
1671396516
1671396516
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
1-4-2-6-
3-5
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
153.3
150.3
156.3
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
153.6
150.6
156.6
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Injection quantity adjustment_03
Adjusting point
C
Rack position
10.9
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
149.6
147.6
151.6
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Injection quantity adjustment_04
Adjusting point
D
Rack position
10.9
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
145.5
142.5
148.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Injection quantity adjustment_05
Adjusting point
E
Rack position
10.1
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
118.6
115.6
121.6
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
F
Rack position
5.7+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
11
10
12
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
10.1
Boost pressure
kPa
6.7
4
6.7
Boost pressure
mmHg
50
30
50
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
10.6
Boost pressure
kPa
10.7
9.4
12
Boost pressure
mmHg
80
70
90
Boost compensator adjustment_03
Pump speed
r/min
500
500
500
Rack position
10.9
Boost pressure
kPa
13.3
13.3
13.3
Boost pressure
mmHg
100
100
100
Timer adjustment
Pump speed
r/min
700
Advance angle
deg.
0.3
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
850
Advance angle
deg.
0.5
0.1
0.9
Timer adjustment_04
Pump speed
r/min
1000
Advance angle
deg.
1.7
1.3
2.1
Timer adjustment_05
Pump speed
r/min
1150
Advance angle
deg.
3
2.6
3.4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Adjust with speed control lever at full position (minimum-maximum speed specification)
(2)Adjust with the load control lever in the full position (variable speed specification).
(3)Rack limit using stop lever
(4)Boost pressure: BP1
(5)Damper spring setting: DL
(6)Boost pressure: not less than BP2
(7)Boost compensator stroke: BCL
(8)Main spring setting
----------
BP1=(13.3)kPa((100)mmHg) DL=4.7-0.2mm BP2=6.7-2.7kPa(50-20mmHg) BCL=0.8mm
----------
----------
BP1=(13.3)kPa((100)mmHg) DL=4.7-0.2mm BP2=6.7-2.7kPa(50-20mmHg) BCL=0.8mm
----------
Speed control lever angle
F:Full speed
I:Idle
----------
----------
a=11deg+4deg-3deg b=22deg+-4deg
----------
----------
a=11deg+4deg-3deg b=22deg+-4deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=32.5deg+-5deg b=42deg+-3deg
----------
----------
a=32.5deg+-5deg b=42deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa (non-injection rack position)
----------
aa=2mm
----------
a=26deg+-5deg b=29deg+-3deg c=(26deg)
----------
aa=2mm
----------
a=26deg+-5deg b=29deg+-3deg c=(26deg)
Information:
Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 7. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for service bolt (12) 185-3241 O-Ring Seal
Replace tie bolt (6) with the temporary service bolt (9) that is provided in the service kit.Note: The service bolt that is provided in the kit has an undersized bolt head. The service bolt prevents the body of the HEUI pump from separating during service. Do not remove the service bolt until the fuel transfer pump has been completely reinstalled.
Tighten the service bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the service bolt. The aluminum housing of the pump could be damaged.
After installing the service bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) SealInstalling the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 4 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 5 g01132957
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.
Illustration 6 g01132969
Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten