106661-5420 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615420

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5420 1066615420

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Service parts 106661-5420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5260

3. GOVERNOR 105487-4060

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5950

11. Nozzle and Holder 16600-96510

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5580

15. NOZZLE SET

Include in #1:

106661-5420 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5420 1066615420

Zexel num

Bosch num

Firm num

Name

106661-5420

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 105780-8140

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

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12.2

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 122.3 120.3 124.3

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Rack limit using the stop lever: R1 (4)Excess fuel setting for starting: SXL (5)Damper spring setting: DL (6)Variable speed specification: idling adjustment (7)Fix the lever at the full-load position at delivery. (8)Main spring setting
----------
RT=1 TH=1.8mm R1=14+-0.1mm SXL=12.2+0.2mm DL=5.5-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the speed at aa, set the stopper bolt (2)Set the pump speed at bb. (3)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=275r/min bb=1150r/min
----------
a=31deg+-5deg b=23deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=15deg+-5deg b=40.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa (2)Rack position bb
----------
aa=50mm bb=14+-0.1mm
----------
a=34.5deg+-5deg b=36.5deg+-3deg

Timing setting

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

----------
a=(30deg)

Information:

Determine the fuel rail pressure and the injector test engine speed (where the peak pressure was selected). Typically, pressure will start building after 2 to 5 seconds and then there should be sampling for 5 more seconds. Illustration 7 shows an example of selecting the peak pressure and corresponding speed.
Calculate the speed change of the injector test as follows:Injector test speed change equals injector test engine speed minus pump test engine speed.
Determine injector pressure correction using the injector test speed change and Table 5. This will correct for pressure change as speed changes.
Table 5
Injector Pressure Correction Based on Speed Change
Engine speed change (rpm) 0-5 6-10 11-15 16-20 21-25 26-30 31-35
Six-cylinder pressure correction 283 kPa (41 psi) 896 kPa (130 psi) 1455 kPa (211 psi) 2013 kPa (292 psi) 2572 kPa (373 psi) 3130 kPa (454 psi) 3689 kPa (535 psi)
Four-cylinder pressure correction 159 kPa (23 psi) 510 kPa (74 psi) 834 kPa (121 psi) 1151 kPa (167 psi) 1469 kPa (213 psi) 1793 kPa (260 psi) 2110 kPa (306 psi)
If the injector test engine speed is lower than pump test engine speed, then correct the injector pressure by adding the correction as follows:Injector corrected pressure equals injector test pressure plus injector pressure correction.
If the injector test engine speed is higher than pump test engine speed (as can happen when a battery booster is used), then correct the injector test pressure by subtracting the pressure correction as follows:Injector corrected pressure equals injector test pressure minus injector pressure correction.
Calculate injector leakage ratio as follows:Injector leakage ratio equals injector corrected pressure divided by pump test rail pressure.If the Injector leakage ratio is less than 0.85, the injector must be replaced, if the injector leakage is greater than 0.85 the injector is within the required parameters.Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector.
Proceed to the next injector to be checked. Repeat Step 1 through Step 8 for the remaining electronic unit injectors to be tested.
Remove components of 362-9754 Test Kit from the engine. Replace any fuel injection lines that were removed during the procedures. Refer to Disassembly and Assembly, Fuel Injection Lines - Install for the correct procedure.
Reconnect the electronic unit injector harness connectors.Test Kit Data Sheet
Table 6
Fuel Injection Pump Tests Pump Test Rail Pressure Pump Test Engine Speed Minimum Cranking Pressure (MCP) Service
From Pump Test Datalog From Pump