106671-5500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066715500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-5500 1066715500

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Service parts 106671-5500 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0800

3. GOVERNOR 105407-5940

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 1660096514

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:

106671-5500 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-5500 1066715500

Zexel num

Bosch num

Firm num

Name

106671-5500

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 9.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 148.5 146.5 150.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 127 127

Boost pressure mmHg 950 950

Injection quantity adjustment_02

Adjusting point D

Rack position 9

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 E

Rack position 6.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 39 38 40

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

Boost pressure kPa 6.7 1.4 12

Boost pressure mmHg 50 10 90

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 9.7

Boost pressure kPa 46.7 44 49.4

Boost pressure mmHg 350 330 370

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position (10.7)

Boost pressure kPa 113 113 113

Boost pressure mmHg 850 850 850

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. 1.5 1 2

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: 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)Main spring setting (6)Set idle sub-spring (7)Rack difference between N = N1 and N = N2
----------
K=18 BCL=(1.7)mm L1=10.7+-0.1mm N1=1050r/min N2=650r/min
----------

Speed control lever angle

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

----------
a=(14deg)+-5deg b=(19deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0.
----------
aa=10.7+-0.1mm
----------
a=(8deg) b=(18deg)

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:

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap on the radiator is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Drain the coolant from the cooling system into a suitable container for disposal. 2. Disconnect the water supply hose from the water pump inlet.3. Remove connector pipe (1). Remove two bolts (2) and the washers. Remove oil fill pipe (3).4. Remove bolts and washers (4) and water pump (5) from the front housing. The following steps are for the installation of the water pump.5. Check the condition of the O-ring seal used between the water pump and the front housing. If the seal is worn or damaged, use a new part for replacement. Install the O-ring seal on the water pump.6. Lubricate the bore in the front housing with clean engine oil. Put the water pump in position in the front housing. Install bolts (4) and the washers that hold the water pump. Tighten the bolts evenly.7. Check the condition of the gaskets used with connector pipe (1) and oil fill pipe (3). If the gaskets are worn or damaged, use new parts for replacement.8. Position the gasket and connector pipe (1) on the engine. Install the bolts and washers that hold it.9. Put oil fill pipe (3) in position on the engine. Be sure the gasket is in position between the regulator and oil fill pipe. Install oil fill pipe. Install bolts (2) and the washers.10. Connect the water supply hose to the inlet of the water pump.11. After installation of the alternator, fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.End By:a. Install alternator.Disassemble Water Pump
Start By:Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove". The information is in this manual.
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life
(3) Cover bolts(4) Hex washer(5) Bolt(6) Bearing(7) Gear(8) Retaining ring(9) Impeller(10) Shaft(11) Water seal(12) Oil seal(13) Water pump housing 1. Remove water pump elbow (1). Remove elbow (2). 2. Remove cover bolts (3). Carefully separate the housing from the cover. 3. Hold hex washer (4). Remove hex socket head bolt (5). 4. Remove bearing (6). 5. Use Tooling (A) to remove gear (7). 6. Use Tooling (B) to remove retaining ring (8). Remove inner bearing (6). 7. Use Tooling (C) to remove impeller (9). 8. Use a hydraulic press and remove shaft assembly (10). 9. Remove water seal (11). 10. Remove oil seal (12).Assemble Water Pump
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
(3) Cover bolts(4) Hex washer(5) Bolt(6) Bearing(7) Gear(8) Retaining ring(9) Impeller(10) Shaft(11) Water seal(12) Oil seal(13) Water pump housing1. Use