106671-5441 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715441

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-5441 1066715441

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Service parts 106671-5441 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0800

3. GOVERNOR 105407-5850

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105681-1740

6. COUPLING PLATE 105662-1200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7130

11. Nozzle and Holder 16600-96514

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}

13. NOZZLE-HOLDER 105031-4630

14. NOZZLE

105015-6340

15. NOZZLE SET

Include in #1:

106671-5441 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5441 1066715441

Zexel num

Bosch num

Firm num

Name

106671-5441

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 10

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 156.5 154.5 158.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 140 140

Boost pressure mmHg 1050 1050

Injection quantity adjustment_02

Adjusting point C

Rack position 9.4

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 126 123 129

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_03

Adjusting point D

Rack position 5.5+-0.5

Pump speed r/min 420 420 420

Average injection quantity mm3/st. 12.5 11.5 13.5

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 9.4

Boost pressure kPa 10 4.7 15.3

Boost pressure mmHg 75 35 115

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 10.1

Boost pressure kPa 50 47.3 52.7

Boost pressure mmHg 375 355 395

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position (11.3)

Boost pressure kPa 127 127 127

Boost pressure mmHg 950 950 950

Timer adjustment

Pump speed r/min 750+80

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 1.5 1 2

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)Boost compensator stroke: BCL (4)At excess fuel lever operation (at boost pressure 0): L1 (5)Set idle sub-spring (6)Main spring setting
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K=14 BCL=(1.9)mm L1=10.9+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=6deg+-5deg b=17deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=26.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa (at boost pressure = bb)
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aa=10.9+-0.1mm bb=0kPa(0mmHg)
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a=(10deg) b=(18deg)

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
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L=6.7mm
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a1=A a2=B a3=C a4=- r1=650r/min r2=650r/min r3=650r/min r4=- Q1=156.5+-2mm3/st Q2=154.5+-2mm3/st Q3=128.5+-2mm3/st Q4=- c1=+-4% c2=+-4% c3=+-4% c4=- a5=22 a6=21 a7=20 a8=19 a9=18 a10=- a11=- a12=- a13=- a14=- a15=- r5=1000r/min r6=1050r/min r7=1000r/min r8=950r/min r9=900r/min r10=- r11=- r12=- r13=- r14=- r15=- R5=1180+-27r/min R6=1130+-26r/min R7=1075+-25r/min R8=1020+-23r/min R9=965+-22r/min R10=- R11=- R12=- R13=- R14=- R15=-

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)

Information:

Do not bend or add stress to the shaft when nut is loosened or tightened.
d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3263 Retaining Compound.e. Tighten nut to 4 N m (30 lb in).f. Tighten nut more 90° rotation.(6) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(7) Bore in housing (new) ... 24.994 to 25.006 mm (.9840 to .9845 in) Outside diameter of the bearing (new) ... 24.882 to 24.892 mm (.9796 to .9800 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Tighten both band clamps (that hold the compressor and turbine housings to the cartridge group) with procedure that follows: a. Tighten to ... 14 1.1 N m (125 10 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 14 1.1 N m (125 10 lb in)
Do not overtighten the clamps.
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 5 N m (40 4 lb ft) Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.Turbocharger S3B And C3B
(1) End play for shaft (new) ... 0.102 0.025 mm (.004 .001 in) Maximum permissible end play (worn) ... 0.20 mm (.008 in)(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 0.03 mm (.211 .001 in)(3) Diameter of shaft (new) ... 12.697 to 12.705 mm (.4999 to .5002 in) Bore in the bearing (new) ... 12.741 to 12.748 mm (.5016 to .5019 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)(5) Install the compressor wheel (at room temperature) as follows: a. Put compressor wheel on the shaft.b. Put a small amount of clean engine oil on the threads.c. Tighten the nut to 14 to 17 N m (125 to 150 lb in).d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3263 Retaining Compound.e. Tighten nut to a torque of ... 24 2 N m (216 12 lb in)
Do not bend or add stress to the shaft when the nut is loosened or tightened.
(6) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(7) Bore in housing (new) ... 20.744 to 20.757 mm (.8167 to .8172 in) Outside diameter of the bearing (new) ... 20.630 to 20.643 mm (.8122 to .8127 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 5 N m (40