106661-5460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615460 1679096515

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5460 1066615460

NISSAN-DIESEL 1679096515 1679096515

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Service parts 106661-5460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-1300

3. GOVERNOR 105407-4240

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105614-4320

6. COUPLING PLATE 105662-0761

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4570

11. Nozzle and Holder 1660096502

12. Open Pre:MPa(Kqf/cm2) 22.6(230)

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-4170

15. NOZZLE SET

Include in #1:

106661-5460 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5460 1066615460

NISSAN-DIESEL 1679096515 1679096515

Zexel num

Bosch num

Firm num

Name

106661-5460

1679096515 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6T04 * K

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 132424-0620

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 3.2 3.15 3.25

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 11.5

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 46.7 46.7

Boost pressure mmHg 350 350

Injection quantity adjustment_02

Adjusting point B

Rack position 11.5+-0. 5

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 151.2 145.2 157.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 46.7 46.7

Boost pressure mmHg 350 350

Injection quantity adjustment_03

Adjusting point C

Rack position 10.3

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 113.5 110.5 116.5

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_04

Adjusting point D

Rack position 6.1+-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 10.3

Boost pressure kPa 6.7 4.7 8.7

Boost pressure mmHg 50 35 65

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (11.5)

Boost pressure kPa 20 13.3 26.7

Boost pressure mmHg 150 100 200

Timer adjustment

Pump speed r/min 350

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 2.5 2 3

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Remarks
Finish

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)When excess fuel lever for starting operates (at boost pressure 0): SXL
----------
K=18 SXL=12.1+-0.1mm
----------

Speed control lever angle

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

----------
a=18deg+-5deg b=28deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Drive side
----------
aa=12.1+-0.1mm
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a=10deg+-5deg b=(20deg)

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=6.1mm
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a1=A a2=B a3=C a4=D a5=- a6=- r1=750r/min r2=750r/min r3=750r/min r4=750r/min r5=- r6=- Q1=152+-2mm3/st Q2=149.6+-2mm3/st Q3=139+-2mm3/st Q4=120.1+-2mm3/st Q5=- Q6=- c1=+-4% c2=+-4% c3=+-4% c4=+-4% c5=- c6=- a7=23 a8=22 a9=21 a10=20 a11=19 a12=18 a13=17 a14=16 a15=15 a16=14 a17=13 a18=12 a19=- a20=- r7=1150r/min r8=1100r/min r9=1050r/min r10=1000r/min r11=950r/min r12=900r/min r13=850r/min r14=800r/min r15=750r/min r16=700r/min r17=650r/min r18=600r/min r19=- r20=- R7=1235+-28r/min R8=1180+-27r/min R9=1130+-26r/min R10=1075+-25r/min R11=1020+-23r/min R12=965+-22r/min R13=915+-22r/min R14=860+-20r/min R15=805+-18r/min R16=750+-17r/min R17=695+-16r/min R18=645+-15r/min R19=- R20=-

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:

1. Disconnect the fuel outlet line (1) and fuel inlet line (3) from the priming pump.2. Disconnect the fuel line (2) from pump.3. Remove the bolts (4) from pump.4. Remove the fuel transfer pump.5. Remove the fuel lines (1) and (3) from pump.Install Fuel Transfer Pump
1. Install the two fuel lines in transfer pump.2. Put the fuel transfer pump in position in the accessory drive housing, and install the two bolts.3. Connect the two fuel lines to priming pump.4. Connect the fuel line to transfer pump.Disassemble Fuel Transfer Pump
start by: a) remove fuel transfer pump 1. Remove the nut (2), gear (3), and key.2. Remove the cage (1). Remove the O-ring seals from the cage.3. Use tool setup (A) to remove the bearing and seals from cage (1).4. Remove the cover (4).
Be careful during disassembly and assembly of pump to prevent damage to the contacting surfaces of the cover (4) and the pump body.
5. Remove the bolt (5), spring, and ball for the check valve for the priming pump. 6. Remove the gear (7), and gear and shaft assembly (6) from pump body. 7. Use tool setup (A) to remove the bearing from the pump body.Assemble Fuel Transfer Pump
1. Clean all parts thoroughly before assembling the pump. 2. Use tool setup (A) to install the bearing in the pump body.3. Put the gear, and gear and shaft assembly in position in pump body.4. Put a thin amount of 8S6747 Liquid Gasket Material on the face of body assembly that is against the cover.
Do not let the liquid gasket material get into the pump.
5. Put the cover into position on pump body and install the bolts. The gear and shaft assembly must turn freely after the bolts in cover have been tightened.6. Install the check valve ball, spring, and bolt for the priming pump in the cover. 7. Use tool setup (B) to install the seals in cage. Install the two seals with the lips of seals toward each other.8. Use tool setup (A) to install the bearing in cage assembly. Install the O-ring seals on cage. 9. Put clean oil on O-ring seals and lips of seals. 10. Put the cage assembly in position, and install the woodruff key, gear, and nut. Tighten nut to 22 5 lb.ft. (3.0 0.7 mkg).end by: a) install fuel transfer pump