106671-1368 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066711368 1156021402

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-1368 1066711368

ISUZU 1156021402 1156021402

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Cross reference number

ZEXEL 106671-1368 1066711368

ISUZU 1156021402 1156021402

Zexel num

Bosch num

Firm num

Name

106671-1368
106671-1367

1156021402 ISUZU

INJECTION-PUMP ASSEMBLY
6SD1X *

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 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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.67 3.73

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

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

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 131.5 129.5 133.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 7.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 119.8 117.8 121.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_03

Adjusting point C

Rack position 5.4+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8.2 5 11.4

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 85 85

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 7

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position 8.5

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Boost compensator stroke: BCL (3)Damper spring setting: DL
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SXL=8.6+0.2mm BCL=1.5+-0.1mm DL=4.4-0.5mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N2=800r/min C2=(5.5)deg t1=2--sec. t2=2--sec.
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N1=800++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.5+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

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

----------
a=8deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=35mm
----------
a=15deg+-5deg b=35deg+-3deg

Stop lever angle

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

----------
a=37deg+-5deg b=73deg+-5deg

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1= 5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

(Engine Crankshaft Turns Freely) (Exhaust Smoke Can Be Seen While Starting)
Recommended Procedure
1. Cold Outside Temperatures ... It may be necessary to use starting aids, or to heat engine oil or coolant at temperatures below 10°C (50°F).2. Air in Fuel System ... With air in the fuel system the engine will normally be difficult to start, run rough and release a large amount of white smoke. To remove the air from the fuel system, open the manual bleed valve on the fuel injection pump housing. Operate the priming pump until the flow of fuel from the manual bleed valve is free of air. Close the manual bleed valve and fasten the fuel priming pump. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the cylinder heads, and permit the fuel to come out until it is free of air. Tighten the fuel line nuts. If air is not removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.3. Low Quality Fuel ... Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with a good quality fuel. Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary.4. Low Fuel Pressure ... Change the fuel filter. If the pressure is still low, check the bypass valve in the fuel transfer pump. Debris in the system can make the valve become stationary in the open position.5. Fuel Injection Timing Not Correct ... Check and make necessary adjustments as per Testing and Adjusting section of this Service Manual.6. Valve Adjustment Not Correct ... Check and make necessary adjustments as per Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.64 mm (.025 in).7. Bad Fuel Nozzle(s) ... Remove and test the fuel nozzles.8. Low Compression ... See Misfiring and Running Rough.Exhaust Smoke