Information injection-pump assembly
ZEXEL
106671-6030
1066716030
ISUZU
1156030500
1156030500
Rating:
Cross reference number
ZEXEL
106671-6030
1066716030
ISUZU
1156030500
1156030500
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.5
4.47
4.53
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.5
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
146.5
144.5
148.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
6.5+-0.5
Pump speed
r/min
240
240
240
Average injection quantity
mm3/st.
11.5
8.3
14.7
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
146.5
144.5
148.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
140.5
134.5
146.5
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R2-1
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2(R1-1.
4)
Boost pressure
kPa
13.3
13.3
13.3
Boost pressure
mmHg
100
100
100
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
875
Advance angle
deg.
1.5
1
2
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=AD02 BCL=1+-0.1mm
----------
----------
T1=AD02 BCL=1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=24.5deg+-5deg b=(34deg)+-3deg
----------
aa=35mm
----------
a=24.5deg+-5deg b=(34deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=22deg+-5deg b=41deg+-5deg
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=22deg+-5deg b=41deg+-5deg
0000001501 TAMPER PROOF
(A): Rotation tamper proof
(B): Full-speed setting
1. Back off the full-speed set bolt.
2. Confirm that the tamper setting position is N1, R1, Q1.
3. At that time, record the angle of the speed lever.
4. After confirming the above setting, set full speed.
----------
N1=- R1=6.2+-1mm Q1=-
----------
----------
N1=- R1=6.2+-1mm Q1=-
----------
0000001601 TAMPER PROOF
SW:Inner hexagonal SW14
(F): Apply thread lock adhesive .
(G): Full tamper proof
(H): Full boost (Full rack)
(I): 0 boost
1. Mount (C) and (D) after adjusting the boost compensator.
2. Back off the load lever set screw L1 from the end face of the governor housing..
3. Apply boost pressure and set the full load at tamper set position point aa to obtain N1, Q1 and Ra using the screw C.
4. Fix using the nut (D).
5. Next, after adjusting the stop lever, confirm the point aa.
6. Reset the load lever to the full boost rack.
7. After completion of setting, seal using the plug (E).
----------
L1=6+1 N1=1100r/min Ra=R1(11.5)+0.65mm Q1=- aa=F
----------
T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)
----------
L1=6+1 N1=1100r/min Ra=R1(11.5)+0.65mm Q1=- aa=F
----------
T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)
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=10deg
----------
a=(50deg)
----------
aa=10deg
----------
a=(50deg)
Information:
Temporary corrections to the charts in this book will be printed in the publication ENGINE NEWS. Announcement for revised reprints of this book will be made in PREVIEW.These instructions are intended to acquaint you with the content of the rack setting charts. A description is given of the information to be found under each column heading. Read these instructions carefully so you can better understand the information presented.After reading and understanding these instructions, use the following suggestions to aid in the actual use of the rack setting charts.1. Determine and write down the engine model and engine serial number.2. Locate the correct rack setting chart.3. Locate the correct segment of the chart being used. Particular attention must be focused on the model and serial number.4. Read all notes pertaining to the engine being repaired. The notes are just as important as any other information that is presented on the rack setting chart.Column Headings
Column headings and arrangement of material can vary from chart to chart according to data requirements for the engines. A brief description of each column heading, note and symbol follows. See Fig. 1.Model
The MODEL column lists the description of the engine, and the serial number range to which the data applies. Be sure to use the data from the correct serial number range for the engine being repaired.Engine Full Load RPM
The column lists the engine speed (under load) at which the rack is positioned to permit maximum allowable amount of fuel to the engine per unit of time. Turbocharger speed, inlet manifold pressure and horsepower output are at their maximum for the listed rack setting. A tolerance of 10 RPM is allowed.Engine High Idle RPM
This column lists the high idle speed of the bare engine when driving a dynamometer. Use the figures in the chart when adjusting high idle in the truck. A tolerance of 30 RPM is allowed in most applications.Brake Horsepower
This column lists the power available at the flywheel, without fan, and within the limitations indicated in the charts. A tolerance of 3% of this value is normal from a new or reconditioned engine.
Fig. 1Rack Setting
The rack setting is the distance the rack must travel from the centered (sometimes referred to as zero) position, to supply sufficient fuel, to produce the expected power output of the engine. Rack setting is controlled by a stop bar or torque spring that is located within the governor. The stop bar and/or torque spring limits the maximum travel of the fuel rack. Rack setting procedure is explained and illustrated in the TESTING AND ADJUSTING Section of the applicable service manual.All rack settings are plus (+) settings unless otherwise indicated with a minus (-) sign. See Fig. 2.Torque Spring And Spacer
This column lists the part number and thickness of the torque spring, and only those spacers or shims installed between the torque spring and stop. Any shims located behind the stop are not listed. The dimensions are in inches and are for means of identification.
Fig.
Column headings and arrangement of material can vary from chart to chart according to data requirements for the engines. A brief description of each column heading, note and symbol follows. See Fig. 1.Model
The MODEL column lists the description of the engine, and the serial number range to which the data applies. Be sure to use the data from the correct serial number range for the engine being repaired.Engine Full Load RPM
The column lists the engine speed (under load) at which the rack is positioned to permit maximum allowable amount of fuel to the engine per unit of time. Turbocharger speed, inlet manifold pressure and horsepower output are at their maximum for the listed rack setting. A tolerance of 10 RPM is allowed.Engine High Idle RPM
This column lists the high idle speed of the bare engine when driving a dynamometer. Use the figures in the chart when adjusting high idle in the truck. A tolerance of 30 RPM is allowed in most applications.Brake Horsepower
This column lists the power available at the flywheel, without fan, and within the limitations indicated in the charts. A tolerance of 3% of this value is normal from a new or reconditioned engine.
Fig. 1Rack Setting
The rack setting is the distance the rack must travel from the centered (sometimes referred to as zero) position, to supply sufficient fuel, to produce the expected power output of the engine. Rack setting is controlled by a stop bar or torque spring that is located within the governor. The stop bar and/or torque spring limits the maximum travel of the fuel rack. Rack setting procedure is explained and illustrated in the TESTING AND ADJUSTING Section of the applicable service manual.All rack settings are plus (+) settings unless otherwise indicated with a minus (-) sign. See Fig. 2.Torque Spring And Spacer
This column lists the part number and thickness of the torque spring, and only those spacers or shims installed between the torque spring and stop. Any shims located behind the stop are not listed. The dimensions are in inches and are for means of identification.
Fig.