Information injection-pump assembly
ZEXEL
106682-1021
1066821021
ISUZU
1156033041
1156033041
Rating:
Service parts 106682-1021 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
11.
Nozzle and Holder
1-15300-387-1
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Include in #1:
106682-1021
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-1021
1066821021
ISUZU
1156033041
1156033041
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
134424-4320
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.8
2.75
2.85
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
12.8
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
532
528
536
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
167
167
Boost pressure
mmHg
1250
1250
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.8+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
10.5
7.3
13.7
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
230
230
270
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
9.45
Boost pressure
kPa
69.3
66.6
72
Boost pressure
mmHg
520
500
540
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
(12.8)
Boost pressure
kPa
153
153
153
Boost pressure
mmHg
1150
1150
1150
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
(4)Main spring setting
----------
BCL=(3.35)mm
----------
----------
BCL=(3.35)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=135mm
----------
a=(2.5deg)+-5deg b=(14deg)+-5deg
----------
aa=135mm
----------
a=(2.5deg)+-5deg b=(14deg)+-5deg
0000000901
F:Full load
(1)Fix using the stopper bolt.
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=71deg+-5deg
----------
----------
a=27deg+-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)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
POSITIONING PIN BEARING
MARKS FOR TIGHTENING CONNECTING ROD BOLTS(1) Bore in connecting rod for piston pin bearing ... 2.1825 .0005 in.(55.436 0.013 mm) Tight fit between connecting rod eye and piston pin bearing ... .002 to .004 in.(0.05 to 0.10 mm) Connecting rod must be heated for installation of piston pin bearing. Do not use a torch.Heat connecting rod to temperature of ... 350 to 500° F (177 to 260° C) Piston pin bearing junction must be assembled within either area "A" (90 10° from the centerline through the connecting rod bores) as shown.(2) Bore in connecting rod for bearing with nuts tight to specifications (6) ... 4.0748 .0005 in.(103.500 0.013 mm)(3) Distance between center of bearings ... 10.300 .002 in.(261.62 0.05 mm)(4) Bore in bearing for piston pin (new) ... 2.0012 .0003 in.(50.830 0.008 mm) Diameter of piston pin (new) ... 1.9998 .0002 in.(50.795 0.005