106682-1080 ZEXEL 9 400 617 515 BOSCH INJECTION-PUMP ASSEMBLY 9400617515 1066821080 1156034680

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 515 9400617515

ZEXEL 106682-1080 1066821080

ISUZU 1156034680 1156034680

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Cross reference number

BOSCH 9 400 617 515 9400617515

ZEXEL 106682-1080 1066821080

ISUZU 1156034680 1156034680

Zexel num

Bosch num

Firm num

Name

106682-1080

9 400 617 515

1156034680 ISUZU

INJECTION-PUMP ASSEMBLY
6SD1TCG K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.2 3.17 3.23

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 12.7

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 180 179 181

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 227 227

Boost pressure mmHg 1700 1700

Injection quantity adjustment_02

Adjusting point Z

Rack position 5.6+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 23.5 21.5 25.5

Max. variation between cylinders % 0 -12 12

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 7.7

Boost pressure kPa 40 36 44

Boost pressure mmHg 300 270 330

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position (12.7)

Boost pressure kPa 213 206.3 219.7

Boost pressure mmHg 1600 1550 1650

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator stroke: BCL (3)Set idle sub-spring (with the lever free). (4)Main spring setting
----------
BCL=(5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=135mm
----------
a=(7deg)+-5deg b=(18deg)+-5deg

0000000901

F:Full load (1)Fix using the stopper bolt.
----------

----------
a=15deg+-5deg

Stop lever angle

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

----------
a=28deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=19deg
----------
a=(8deg)

Information:

Engine Crankshaft Turns Freely
Exhaust Smoke Can Be Seen While Starting Recommended Procedure
1. Cold Outside Temperatures ... It can be necessary to use starting aids, or to heat engine oil or coolant at temperatures below 10°F (-12°C).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. If the engine will not start, loosen a fuel injection line nut at the valve cover base. With the governor lever in the shutoff position, operate the fuel priming pump until the flow of fuel from the loosened fuel injection line is free of air. Tighten the fuel line nut. Fasten the priming pump and 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 valve cover base until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 5 psi (35 kPa) of air pressure to the fuel tank.
Do not use more than 8 psi (55 kPa) 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