Information injection-pump assembly
ZEXEL
106671-1385
1066711385
ISUZU
1156019865
1156019865
Rating:
Cross reference number
ZEXEL
106671-1385
1066711385
ISUZU
1156019865
1156019865
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
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
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
4.2
4.17
4.23
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
Rack position
(12.2)
Vist
V
1.55
1.55
1.55
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
153.5
151.5
155.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Injection quantity adjustment_02
Rack position
(6+-0.5)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8
4.8
11.2
Max. variation between cylinders
%
0
-13
13
Test data Ex:
Governor 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=(5.5deg) 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
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L=1-0.2mm N2=800r/min C2=(5.5deg) 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
0000000901
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
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a=(40deg)
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a=(40deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:
Install Water Pump
1. Put the gasket and water pump (1) in position in the timing gear cover. 2. Install the pointer and bolts to hold the water pump.3. Put the vee belts in position on the engine.4. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of the vee belts. Tighten new belts until the gauge indication is 120 5. Operate the engine at high idle for a minimum of 30 minutes after Step 5. Make another adjustment of the belt tension. The correct gauge indication for used belts is 90 10. Tighten the bolts that hold the alternator.5. Fill the cooling system with coolant to the correct level.Disassemble Water Pump
a) remove water pump1. Hold the pump shaft in a vise as shown and remove the bolt and pulley (1). 2. Use tooling (A) and a press to remove the shaft, seal and impeller from housing (2) as shown.
The press must have a guard. The guard has been removed for photo illustration.
3. Remove bearing (3) from housing (2). 4. Remove spacer (4) from housing (2). 5. Use tool (B) to remove ring (5) from housing (2). Remove bearing (6) from housing (2).6. Use a press and tool (C) to remove the shaft and seal assembly from impeller (7) as shown. 7. Install the seal assembly and shaft in housing (2) as shown. Use a press and tool (C) to remove the shaft from the seal assembly. Assemble Water Pump
1 Install bearing (1) in housing (3). Use tool (A) to install ring (2) that holds bearing (1) in position. 2 Install spacer (4) in housing (3). 3 Make sure the outside diameter of bearing (5) and the bore in housing (3) are clean and dry. Install bearing (5) in housing (3). Fill the chamber area between the housing and outside diameter of bearing (5) with 7M7456 Bearing Mount. Remove the excess bearing mount from the housing. 4. Turn the pump housing over and make sure that the bores in the bearings and spacer are in alignment. Install the shaft through the bearings from the impeller side of the housing. The shaft to bearing clearance can be 0.018 mm (.0007 in.) loose to 0.008 mm (.0003 in.) tight. If it is necessary to use a press to install the shaft, make sure the inner races of the bearings have support. 5. Install pulley (6) on the shaft and tighten the bolt to a torque of 75 7 N m (55 5 lb.ft.). 6. Put a new seal assembly (7) on the shaft as shown.7. Use tool (B) and a press to install the seal assembly in housing (3). Do not use a hammer to install the seal. 8. Put tool (D) between impeller (8) and the pump housing.9. Use a press and tool (C) to install impeller (8) on the shaft until tool (D) can just be moved between the housing and impeller. 10. If
1. Put the gasket and water pump (1) in position in the timing gear cover. 2. Install the pointer and bolts to hold the water pump.3. Put the vee belts in position on the engine.4. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of the vee belts. Tighten new belts until the gauge indication is 120 5. Operate the engine at high idle for a minimum of 30 minutes after Step 5. Make another adjustment of the belt tension. The correct gauge indication for used belts is 90 10. Tighten the bolts that hold the alternator.5. Fill the cooling system with coolant to the correct level.Disassemble Water Pump
a) remove water pump1. Hold the pump shaft in a vise as shown and remove the bolt and pulley (1). 2. Use tooling (A) and a press to remove the shaft, seal and impeller from housing (2) as shown.
The press must have a guard. The guard has been removed for photo illustration.
3. Remove bearing (3) from housing (2). 4. Remove spacer (4) from housing (2). 5. Use tool (B) to remove ring (5) from housing (2). Remove bearing (6) from housing (2).6. Use a press and tool (C) to remove the shaft and seal assembly from impeller (7) as shown. 7. Install the seal assembly and shaft in housing (2) as shown. Use a press and tool (C) to remove the shaft from the seal assembly. Assemble Water Pump
1 Install bearing (1) in housing (3). Use tool (A) to install ring (2) that holds bearing (1) in position. 2 Install spacer (4) in housing (3). 3 Make sure the outside diameter of bearing (5) and the bore in housing (3) are clean and dry. Install bearing (5) in housing (3). Fill the chamber area between the housing and outside diameter of bearing (5) with 7M7456 Bearing Mount. Remove the excess bearing mount from the housing. 4. Turn the pump housing over and make sure that the bores in the bearings and spacer are in alignment. Install the shaft through the bearings from the impeller side of the housing. The shaft to bearing clearance can be 0.018 mm (.0007 in.) loose to 0.008 mm (.0003 in.) tight. If it is necessary to use a press to install the shaft, make sure the inner races of the bearings have support. 5. Install pulley (6) on the shaft and tighten the bolt to a torque of 75 7 N m (55 5 lb.ft.). 6. Put a new seal assembly (7) on the shaft as shown.7. Use tool (B) and a press to install the seal assembly in housing (3). Do not use a hammer to install the seal. 8. Put tool (D) between impeller (8) and the pump housing.9. Use a press and tool (C) to install impeller (8) on the shaft until tool (D) can just be moved between the housing and impeller. 10. If