106671-1280 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066711280 1156011053

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-1280 1066711280

ISUZU 1156011053 1156011053

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Cross reference number

ZEXEL 106671-1280 1066711280

ISUZU 1156011053 1156011053

Zexel num

Bosch num

Firm num

Name

106671-1280
106671-1282

1156011053 ISUZU

INJECTION-PUMP ASSEMBLY
6RB2 *

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 134424-1920

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 4.17 4.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point B

Rack position 6.7

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 124.2 122.2 126.2

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 4.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.2 7 13.4

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 157 157

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_04

Adjusting point E

Rack position 6.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 112.7 109.7 115.7

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Timer adjustment

Pump speed r/min (830)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

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: SXL (3)Rack difference between N = N1 and N = N2
----------
DL=2.5-0.5mm SXL=(9.2)mm N1=800r/min N2=500r/min
----------

Speed control lever angle

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

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

0000000901

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

----------
a=31deg+-3deg b=55deg+-5deg

Stop lever angle

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

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

Timing setting

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(60deg)

Information:

preparatory steps: a) remove rocker shaft assemblyb) remove water temperature regulator1. Disconnect the fuel ratio control sensing line (1). Remove the sensing line clamp bolt (2). 2. Disconnect the turbocharger oil supply line (3) and the oil drain line (4).3. Remove the fuel injection lines (5) and install protective caps.4. Disconnect the air compressor water return line (8). 5. Remove the retaining bolts (7) and the fan drive mounting bracket (6).6. Remove the cylinder head retaining bolts. Attach a hoist and remove the cylinder head assembly-weight 240 lbs. (109,1 kg).Install Cylinder Head Assembly
1. Thoroughly clean the sealing surfaces of the cylinder head and cylinder block. Position a new head gasket on the engine and install the cylinder head assembly.2. Install the push rods and rocker shaft assembly.3. Coat the threads of the cylinder head retaining bolts with 4S9416 Anti-Seize Compound. Install bolts and washers, and tighten them in the following sequence: 1 - Tighten all numbered bolts in numerical order to 115 lb. ft. (15,9 mkg).2 - Retighten all numbered bolts in numerical order to 175 5 lb. ft. (24,2 0,7 mkg).3 - Finally, retighten all numbered bolts (hand torque only) in numerical order to 175 5 lb. ft. (24,2 0,7 mkg).4 - Tighten all lettered bolts in alphabetical order to 22 lb. ft. (3,0 mkg).5 - Retighten all lettered bolts in alphabetical order to 32 5 lb. ft. (4,4 0,7 mkg).6 - Finally, retighten all lettered bolts (hand torque only) in alphabetical order to 32 5 lb. ft. (4,4 0,7 mkg).4. Adjust the inlet and exhaust valve clearance as covered in INSTALL ROCKER SHAFT ASSEMBLY AND PUSH RODS.5. Connect the air compressor water return line.6. Install the fuel lines and tighten the retaining nuts to 30 5 lb. ft. (4,1 0,7 mkg).7. Connect the turbocharger oil supply line and the oil drain line.8. Connect the fuel ratio control sensing line and install the sensing line clamp bolt.9. Install the fan drive mounting bracket and retaining bolts.concluding steps: a) install water temperature regulatorb) install valve cover