106661-5470 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615470

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5470 1066615470

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Service parts 106661-5470 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-1300

3. GOVERNOR 105306-1140

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105614-4220

6. COUPLING PLATE 105662-0761

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4570

11. Nozzle and Holder 16600-96502

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

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-4170

15. NOZZLE SET

Include in #1:

106661-5470 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5470 1066615470

Zexel num

Bosch num

Firm num

Name

106661-5470

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 3.2 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 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 26.7 26.7

Boost pressure mmHg 200 200

Injection quantity adjustment_02

Adjusting point B

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 26.7 26.7

Boost pressure mmHg 200 200

Injection quantity adjustment_03

Adjusting point C

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 300 300 300

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 300 300 300

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 300 300 300

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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Boost compensator stroke: BCL (2)Rack limit using stop lever (3)Damper spring setting: DL
----------
BCL=0.8+-0.1mm DL=4.7-0.2mm
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0000000901

F:Full load I:Idle (1)Stopper bolt setting
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----------
a=12deg+-5deg b=21deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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----------
a=3deg+-5deg b=32deg+-3deg

0000001501 ACS

(A) Set screw (B) Push rod 1 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. 2. Adjustment following governor installation (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
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N1=1150r/min L1=(0.6~0.9)mm
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R1=10.9mm R2=(10.1)mm P1=80kPa(600mmHg) P2=58+-0.7kPa(435+-5mmHg) Q1=153.3+-3cm3/1000st Q2=134.2+-3cm3/1000st

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:

2. Remove the two bolts (1) from transfer pump, and pull the pump out of accessory drive housing.3. Remove the four bolts and lock from retainer (3). Remove the retainer.4. Remove the drive gear (2). 5. Remove the two bolts, locks, and plate (5).6. Remove the variable timing unit (4) from the accessory drive housing.Install Variable Timing Unit
1. Put the variable timing unit (1) in position in the accessory drive housing.2. Install the retaining plate, locks, and two bolts.3. Install the drive gear, retainer, lock, and four bolts. Do not tighten the four bolts.4. Make an adjustment to the timing of the camshaft for the fuel injection pump. See FUEL INJECTION PUMP CAMSHAFT TIMING in TESTING AND ADJUSTING. 5. Install the cover (4) on timing gear housing.6. Put the transfer pump (3) in position on the accessory drive housing, and install the two bolts (2).7. Check to be sure all timing pins and bolts have been removed from their timing holes, and are installed in their storage positions.Disassemble Variable Timing Unit
start by: a) remove variable timing unit 1. Push down on retainer (1), and remove the pin (2).2. Remove the retainer and spring. 3. Use a hammer and punch to remove the dowels (4). Remove the two weights.4. Remove the piston and rod assembly (5) from shaft assembly (3).5. Remove the pins from nut and rod.6. Remove the rod, nut, spring, and valve from the piston assembly.Assemble Variable Timing Unit
1. Install the valve, spring, and nut on the piston assembly. Turn the nut until the distance (X) between bottom face of nut and the piston is 1.760 in. (44.7 mm). Drill a .095 .002 in. (2.41 0.05 mm) diameter hole through the nut and the threads of piston assembly. Install the pin in nut. 1. Install the rod tight against the nut. Take a measurement .156 in. (3.96 mm) from top face of nut, and put a mark at this location on rod. Drill a .095 .0.05 mm) diameter hole (1) through the rod and piston assembly at this location. Install the pin in rod.3. Install the piston and rod assembly in the shaft assembly. Install the spring, retainer, and pin in shaft assembly.4. Install the weights and dowels. Use a hammer and punch to fasten both ends of the dowels in place. Both weights must move freely after the dowels have been fastened in place.end by: a) install variable timing unit