106671-1110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066711110 1156009301

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-1110 1066711110

ISUZU 1156009301 1156009301

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Cross reference number

ZEXEL 106671-1110 1066711110

ISUZU 1156009301 1156009301

Zexel num

Bosch num

Firm num

Name

106671-1110

1156009301 ISUZU

INJECTION-PUMP ASSEMBLY
6RB1 * K

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 131424-0220

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 4.2 4.15 4.25

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 B

Rack position 9.4

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 115.6 113.6 117.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.9 9.7 16.1

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.8+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 114.1 111.1 117.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 1.3 0.1 1.3

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting (3)Rack difference between N = N1 and N = N2
----------
DL=4.7-0.5mm N1=1100r/min N2=650r/min
----------

Speed control lever angle

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

----------
a=4deg+-5deg

0000000901

F:Full load I:Idle S:Stop (1)Rack position aa (pump speed bb r/min )
----------
aa=6.2mm bb=0r/min
----------
a=25.5deg+-5deg b=33deg+-3deg c=15deg+-5deg

Stop lever angle

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

----------
a=32deg+-5deg b=64deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(70deg)

Information:

EXHAUST MANIFOLD
1. Locks (four each side). 2. Retaining bolts (eight each side). 3. Exhaust manifold (one each side).Install Exhaust Manifold
1. Clean the exhaust manifold gasket mounting surfaces.2. Position the gasket and exhaust manifold on the engine and install the retaining bolts with locks. Tighten retaining bolts to 32 5 lb. ft. (4.4 0.7 mkg). Bend tabs on locks over flats of retaining bolt heads. Lock tabs must be bent over flats of retaining bolt heads. If necessary to align flats, tighten bolts a maximum additional turn of 30°. Do not loosen bolts to align flats.Disassemble Crankcase Ventilation Valve
1. Remove screws (2) that hold cover (3) on housing (1).
VENTILATION VALVE
1. Housing. 2. Screws (seven). 3. Cover.2. Remove cover (3) and spring (4).
REMOVING COVER
1. Housing. 3. Cover. 4. Spring.3. Remove the piston, sleeve (8), retainer (9), and diaphragm (7) from housing (1) as a unit. Remove inner sleeve (6) and gasket (5) from housing (1).
DISASSEMBLING VALVE
1. Housing. 5. Gasket. 6. Inner sleeve. 7. Diaphragm. 8. Sleeve. 9. Retainer.4. Remove nut (12), washer (13), spacer (11), piston (10), diaphragm (7), and the retainer from sleeve (8).
REMOVING DIAPHRAGM
7. Diaphragm. 8. Sleeve. 10. Piston. 11. Spacer. 12. Nut. 13. Washer.Assemble Crankcase Ventilation Valve
1. Put 5H2471 Gasket Cement on both sides of gasket (5) and install the gasket on housing (1). Install inner sleeve (6) in housing (1).2. Inspect diaphragm (7) for damage. Put piston (10) against side of diaphragm (7) that is stamped "piston side" and put retainer (9) in diaphragm (7).
INSTALLING INNER SLEEVE
1. Housing. 5. Gasket. 6. Inner sleeve.
ASSEMBLING DIAPHRAGM
7. Diaphragm. 9. Retainer. 10. Piston.3. Put the screw through sleeve (8), retainer (9), diaphragm (7), and piston (10). Put spacer (11), washer (13), and nut (12) on the screw and tighten the nut.
ASSEMBLING DIAPHRAGM
7. Diaphragm. 8. Sleeve. 10. Piston. 11. Spacer. 12. Nut. 13. Washer.4. Put 5H2471 Gasket Cement on both sides of the diaphragm (7) to prevent it from distorting and tearing during assembly. Install the assembled diaphragm unit in the inner sleeve (6) and housing (1).
INSTALLING DIAPHRAGM
1. Housing. 5. Gasket. 6. Inner sleeve. 7. Diaphragm. 8. Sleeve. 9. Retainer.5. With the diaphragm unit installed, put spring (4) on the spacer and install cover (3) being sure spring (4) goes over plug (14).
INSTALLING COVER
1. Housing. 3. Cover. 4. Spring. 14. Plug.6. Put screws (2) in housing (1) and tighten the screws.
COVER INSTALLED
1. Housing. 2. Screws (seven). 3. Cover.