106661-5500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5500 1066615500

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Service parts 106661-5500 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5610

3. GOVERNOR 105487-4910

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105636-2050

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:

106661-5500 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5500 1066615500

Zexel num

Bosch num

Firm num

Name

106661-5500

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 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 3.65 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 9

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 117.5 116.5 118.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 9.5 8.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using the stop lever: R1 (5)Excess fuel setting for starting: SXL (N = N1) (6)Damper spring setting
----------
RT=1 TH=2.3mm R1=10.8+0.2mm SXL=9+0.2mm N1=400r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=21deg+-5deg

0000000901

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

----------
a=15deg+-5deg b=29deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb (3)Drive side
----------
aa=50mm bb=10.8+0.2mm
----------
a=26deg+-5deg b=28deg+-5deg

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. Remove the oil outlet line (1) for oil pump.2. Remove the bolts (2) and locks, and remove the oil pump. Weight of oil pump is 40 lb. (17 kg).Install Oil Pump
1. Put the oil pump in position on engine, and install the bolts and locks.2. Install the oil outlet line for pump.end by: a) install oil panDisassemble Oil Pump
start by: a) remove oil pump 1. Remove suction bell (2). 2. Remove cover (4) and screen (5) from suction bell.3. Remove the cover (1) from bypass valve.4. Remove the bypass valve spring and plunger for the oil pump.5. Remove the cotter pin, and loosen nut (3). 6. Install tool setup (A) and make the gear separate from shaft.7. Remove tool setup (A), nut (3), and gear. Remove the woodruff key from shaft. 8. Remove the bolts (6) and locks. Remove cover assembly (7).9. Remove the oil pump gears.10. Remove the bolts (9) and locks. Remove the cover assembly (8).11. Remove the bearings from cover assemblies (7) and (8).Assemble Oil Pump
1. Use tool setup (A) to install the bearings in the cover assemblies. 2. Put cover assembly (1) in position on body, and install the bolts and locks.3. Put clean oil on the oil pump gears and on the bearings in the cover assemblies.4. Put the oil pump gears in position on cover assembly (2), and install the cover assembly. Install the bolts and locks.5. Install the woodruff key in shaft.6. Put the drive gear in position on shaft, and install the nut and washer. Tighten the nut to 60 lb.ft. (8.3 mkg) plus the amount needed to put holes for cotter pin in alignment. Install the cotter pin. 7. Install the bypass valve plunger (3) and spring (4). Install the cover for bypass valve. 8. Put the screen assembly (5) in position in the suction bell, and install the cover.9. Install the suction bell on oil pump.end by: a) install oil pump