Information injection-pump assembly
ZEXEL
106693-6182
1066936182
ISUZU
8943953682
8943953682
Rating:
Cross reference number
ZEXEL
106693-6182
1066936182
ISUZU
8943953682
8943953682
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
105780-8250
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-8620
Overflow valve opening pressure
kPa
206
172
240
Overflow valve opening pressure
kgf/cm2
2.1
1.75
2.45
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
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
3.6
3.57
3.63
Rack position
Point A R=A
Point A R=A
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
11.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
108
106
110
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
Z
Rack position
8+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
12.5
9.3
15.7
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(11.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
108
107
109
Basic
*
Fixing the lever
*
Boost pressure
kPa
72
72
Boost pressure
mmHg
540
540
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
108
104
112
Fixing the lever
*
Boost pressure
kPa
72
72
Boost pressure
mmHg
540
540
Boost compensator adjustment
Pump speed
r/min
525
525
525
Rack position
R2-1.7
Boost pressure
kPa
12
10.7
13.3
Boost pressure
mmHg
90
80
100
Boost compensator adjustment_02
Pump speed
r/min
525
525
525
Rack position
R1-0.2(R
2)
Boost pressure
kPa
58.7
58.7
58.7
Boost pressure
mmHg
440
440
440
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Load
3/5
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Load
3/5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1.5
1
2
Load
3/5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1075
Advance angle
deg.
1.5
1
2
Load
4/5
Timer adjustment_05
Pump speed
r/min
1350
Advance angle
deg.
5.5
5
6
Load
4/5
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=AC30 BCL=1.7+-0.1mm
----------
----------
T1=AC30 BCL=1.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=35mm
----------
a=64deg+-5deg b=38deg+-3deg
----------
aa=35mm
----------
a=64deg+-5deg b=38deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt at rack position = bb, speed = cc and confirm non-injection.
----------
aa=55mm bb=1.5+-0.3mm cc=0r/min
----------
a=14deg+-5deg b=44deg+-5deg
----------
aa=55mm bb=1.5+-0.3mm cc=0r/min
----------
a=14deg+-5deg b=44deg+-5deg
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=7deg
----------
a=(50deg)
----------
aa=7deg
----------
a=(50deg)
Information:
(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance for the pinion ... .020 to .050 in.(0.51 to 1.27 mm)2P6162 24V (Prestolite Number MES 6301 K) 3P110 24V (Prestolite Number MFY 6401 I)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5000 rpmCurrent consumption (draw) with no load: Maximum at 20 V ... 77 A(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for housing bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance between pinion and housing (pinion clearance) ... .020 to .050 in.(0.51 to 1.27 mm)2P2502 24V (Delco-Remy Number 1113393)
Rotation is clockwise when seen from drive end. Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20 V ... 92.5 AMaximum with solenoid at 20 V ... 120.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring* ... 36 to 40 oz.(1.01 to 1.14 kg)(2) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg) ... 80 oz.(2.27 kg)*Minimum for leaf springs 4N3182 24V (Delco-Remy Number 1114711)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20V ... 108.5 AMaximum with solenoid at 20V ... 135.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring ... 80 oz.(2.26 kg)(2) Torque for screws holding nose housing to lever housing ... 13 to 17 lb. ft.(1.8 to 2.4 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5000 rpmCurrent consumption (draw) with no load: Maximum at 20 V ... 77 A(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for housing bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance between pinion and housing (pinion clearance) ... .020 to .050 in.(0.51 to 1.27 mm)2P2502 24V (Delco-Remy Number 1113393)
Rotation is clockwise when seen from drive end. Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20 V ... 92.5 AMaximum with solenoid at 20 V ... 120.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring* ... 36 to 40 oz.(1.01 to 1.14 kg)(2) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg) ... 80 oz.(2.27 kg)*Minimum for leaf springs 4N3182 24V (Delco-Remy Number 1114711)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20V ... 108.5 AMaximum with solenoid at 20V ... 135.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring ... 80 oz.(2.26 kg)(2) Torque for screws holding nose housing to lever housing ... 13 to 17 lb. ft.(1.8 to 2.4 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)