106671-6030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066716030 1156030500


 

Information injection-pump assembly

ZEXEL 106671-6030 1066716030
ISUZU 1156030500 1156030500
106671-6030 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 106671-6030 1066716030
ISUZU 1156030500 1156030500


Zexel num
Bosch num
Firm num
Name
106671-6030 
106671-6031 
 
1156030500  ISUZU
INJECTION-PUMP ASSEMBLY
6SD1-TCE * 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   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
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
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   -
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
 
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
 

Test data Ex:

Governor adjustment

Test data 106671-6030
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
----------

Speed control lever angle

Test data 106671-6030
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

Stop lever angle

Test data 106671-6030
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

0000001501 TAMPER PROOF

Test data 106671-6030
(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=-
----------

0000001601 TAMPER PROOF

Test data 106671-6030
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)

Timing setting

Test data 106671-6030
(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)




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.

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