106661-5511 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615511

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5511 1066615511

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Service parts 106661-5511 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-1300

3. GOVERNOR 105487-5510

4. SUPPLY PUMP 105217-1850

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:

106661-5511 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5511 1066615511

Zexel num

Bosch num

Firm num

Name

106661-5511

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 11.5

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 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_02

Adjusting point B

Rack position 11.5

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 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_03

Adjusting point C

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 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_04

Adjusting point D

Rack position 11.5

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 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_05

Adjusting point E

Rack position 10.3

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 109.5 103.5 115.5

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_06

Adjusting point F

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 300 300 300

Rack position 10.3

Boost pressure kPa 33.3 33.3 33.3

Boost pressure mmHg 250 250 250

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 10.9

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position 11.5

Boost pressure kPa 53.3 53.3 53.3

Boost pressure mmHg 400 400 400

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using stop lever (5)Damper spring setting (6)Variable speed specification: idling adjustment (7)Main spring setting
----------
RT=1 TH=2mm
----------

Speed control lever angle

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

----------
a=11deg+4deg-3deg b=22deg+-4deg

0000000901

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

----------
a=32.5deg+-5deg b=42.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (non-injection rack position) (2)Rack position bb
----------
aa=1.9-0.5mm bb=11.5mm
----------
a=27.5deg+-5deg b=28deg+-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:

2. Disconnect the fuel injection lines (2) from pump housing. Put plugs or caps in all lines and openings.3. Remove the three bolts that hold the fuel filter (3) to the aftercooler housing.4. Disconnect the sensing line (1) for the fuel ratio control from the aftercooler housing. 5. Disconnect the oil supply line (4) from the turbocharger.6. Remove the two water lines (5). 7. Disconnect the water outlet line (6) for the air compressor from the cylinder head.8. Remove the bolts (7) that fasten the cylinder head to the cylinder block. 9. Install 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and remove the cylinder head assembly. Weight of cylinder head assembly is 575 lb. (260 kg). Be sure to install a new gasket between the spacer plate and the cylinder block before installing the cylinder head assembly. See REMOVE and INSTALL SPACER PLATE in DISASSEMBLY AND ASSEMBLY.Install Cylinder Head Assembly
1. Clean the top surface of spacer plate and the surface it is in contact with on the cylinder head.2. Install the cylinder head gasket, water seals, and gasket on timing gear cover. 3. Install the 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and put the cylinder head assembly into position on the engine. Make sure the gear (1) in cylinder head is engaged with drive gear (2). 4. Put 9M3710 Anti-Seize Compound on the threads of the bolts for cylinder head. Install the bolts and washers. Tighten the bolts as follows: 1 -Tighten all bolts in number order to 135 lb.ft. (18.7 mkg).2 -Tighten all bolts in number order to 185 5 lb.ft. (25.6 0.7 mkg).3 -Tighten all bolts using hand torque only to 185 5 lb.ft. (25.6 0.7 mkg). 5. Install the two water lines (4).6. Connect the oil supply line (3) to the turbocharger.7. Connect the water outlet line (5) for the air compressor to the cylinder head. 8. Connect the sensing line (6) for the fuel ratio control to the aftercooler housing.9. Put the fuel filter in position, and install the three bolts.10. Remove the plugs and fuel injection lines and pumps. Connect the fuel injection lines (7) to the pumps. Tighten the nuts on fuel lines to 30 5 lb.ft. (4.1 0.7 mkg).11. Fill the cooling system with coolant.end by: a) install camshaft housingb) install fan drive