106661-5550 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066615550

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106661-5550 1066615550

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Service parts 106661-5550 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5700

3. GOVERNOR 105487-6300

4. SUPPLY PUMP 105227-1050

5. AUTOM. ADVANCE MECHANIS 105636-1710

6. COUPLING PLATE 105662-0751

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder 1660096508

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

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE

105015-5290

15. NOZZLE SET

Include in #1:

106661-5550 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106661-5550 1066615550

Zexel num

Bosch num

Firm num

Name

106661-5550

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 11.6

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 114 113 115

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Remarks
Rack limit using stop lever.

Injection quantity adjustment_02

Adjusting point C

Rack position 7.8+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 10.5 9.2 11.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Rack limit using stop lever (3)Damper spring setting
----------

----------

Speed control lever angle

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

----------
a=20.5deg+-5deg

0000000901

F:Full load I:Idle (1)At center of threaded hole above R = aa (2)Stopper bolt setting
----------
aa=17mm
----------
a=15deg+-5deg b=30.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the hole at R = aa (3)Rack position bb
----------
aa=50mm bb=11.6mm
----------
a=28deg+-5deg b=30deg+-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:

Illustration 23. (2) 141-6737 Adjustable Microgauge.
(7) Top of the 3P-1542 Barrel. (8) 141-6727 Calibration Pump Assembly.1. Place the 141-6737 Adjustable Microgauge on top of the 3P-1542 Barrel of the 141-6727 Calibration Pump Assembly.2. When starting to torque 124-5932 Lever Assemblies, the difference between the face of the 141-6730 Plunger and the 2N-2658 Bolt is about 0.03 mm (.001 in). By setting the 141-6737 Adjustable Microgauge (2) on top of the 141-6727 Calibration Pump Assembly (8), the 141-6737 Plunger can be positioned 25.40 mm (.001 in) above the face of the 3P-1542 Barrel (7).
Illustration 24. (9) 2N-2658 Bolt. (10) 124-5940 Shutoff Lever.3. As the 2N-2658 Bolt (9) is torqued, the 141-6730 Plunger will move down flush with the 3P-1542 Barrel (7) or will be very close to being flush. The calibration can begin from this point. The 2N-2658 Bolts must freely turn in and out of the 124-5940 Shutoff Levers (10) because the calibration depends on where the head of the 2N-2658 Bolt (9) first begins to clamp the 124-5940 Shutoff Lever for the starting point of the calibration.End Play Adjustment
1. In order to save time, use two torque wrenches (color-coding is convenient for distinguishing between the two wrenches). Set one torque wrench to 1.7 N m (15 lb in) and the second torque wrench to N m (35 lb in).
Illustration 25. (1) 124-5941 Shaft. (2) 4N-1826 Dowel on one end of the HSMFS Injection Pump Group. (3) 126-7232 Dowels.2. Adjust the end play in the 124-5941 Shaft. The SMFS 109-0324 Governor And Fuel Injection Pump Group had the dowel in the middle of the sleeve and a large amount of end play in the shaft was acceptable. Now that the 126-7232 Dowels (3) are between two 124-5934 Sleeves, the amount of end play is important. It is necessary that an adjustment be performed to minimize the amount of end play in the 124-5941 Shaft (1).3. The 126-7232 Dowels (3) are located between two 124-5934 Sleeves. Set the 126-7232 Dowels between 0.25 to 0.40 mm (.010 to .016 in) by tapping in the 4N-1826 Dowels (2) until the desired end play is achieved.* With the 1.7 N m (15 lb in) torque wrench, torque the 2N-2658 Bolts to 1.7 N m (15 lb in).* Then use the 4 N m (35 lb in) torque wrench to torque the 2N-2658 Bolts to 3.4 N m (30 lb in) in order to calibrate within specifications.Calibrating the 124-5932 Lever Assemblies.
Illustration 26. Calibrating the 124-5932 Lever Assemblies.
(1) 2N-2658 Bolts. (2) 124-5940 Shutoff Lever.1. Begin with the first 2N-2658 Bolt (1) and turn it until it just begins to clamp (feels snug) on the 124-5940 Shutoff Lever (2).2. Move to the other side and turn the second 2N-2658 Bolt (1) until just begins to clamp (feels snug).* Alternate between sides and tighten each 2N-2658 Bolt about 15 degrees each time.
Illustration 27. View of the HSMFS Injection Pump Group.
(3) Top of the 141-6730 Plunger shown flush with the 3P-1542 Barrel (4).3. Continue until the torque