Information injection-pump assembly
ZEXEL
106871-1063
1068711063
ISUZU
1156029633
1156029633
Rating:
Service parts 106871-1063 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-328-0
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106871-1063
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-1063
1068711063
ISUZU
1156029633
1156029633
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
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
1-8-7-3-
6-5-4-2
Pre-stroke
mm
5.5
5.47
5.53
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 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
145
143.4
146.6
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
6.7+-0.5
Pump speed
r/min
420
420
420
Average injection quantity
mm3/st.
13.5
11.5
15.5
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(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
145
144
146
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.85
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
135.5
131.5
139.5
Fixing the lever
*
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)Damper spring setting
----------
T1=AD63
----------
----------
T1=AD63
----------
Timer 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.
----------
L=1-0.2mm N2=800r/min C2=(8deg) t1=1.5--sec. t2=1.5--sec.
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8deg) t1=1.5--sec. t2=1.5--sec.
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=42.5mm
----------
a=23deg+-5deg b=(32deg)+-3deg
----------
aa=42.5mm
----------
a=23deg+-5deg b=(32deg)+-3deg
Stop lever angle
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=20deg+-5deg b=43deg+-5deg
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=20deg+-5deg b=43deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=1050r/min Ra=R1(12.1)+0.85mm Vist=1.35+-0.14V
----------
----------
V1=5+-0.01V N1=1050r/min Ra=R1(12.1)+0.85mm Vist=1.35+-0.14V
----------
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa
(4)-
----------
aa=4deg
----------
a=(180deg)
----------
aa=4deg
----------
a=(180deg)
Information:
Start By:a. remove valve cover 1. Remove the cover from the flywheel housing and install Tool (A). Turn the crankshaft with Tool (A) until there is no pressure on rocker arm (2).2. Use Tool (B) as shown to move the rocker arm away from push rod (1). Remove push rod (1). 3. Install Tool (C) on the valve lifter. Remove valve lifter (3) from the block. 4. Remove spring guide (4) from the valve lifter.5. Do Steps 1 through 4 again for the other valve lifters and push rods if necessary.Install Valve Lifters & Push Rods
Any time the valve lifter is removed from the machine, a new spring guide must be installed on the valve lifter.1. Install spring guide (1) on valve lifter (2). 2. Put the valve lifter in position on Tool (A) as shown. Make sure spring guide (1) is in position in the groove (slot) in the valve lifter as shown. 3. Use a soft hammer to install Tool (B) over spring guide (1). Make sure the groove in Tool (B) is in alignment with spring guide (1). 4. Put clean engine oil on valve lifter (2). Use Tool (B) to install the valve lifter in the engine block. Make sure the end of the spring guide is in alignment with the small hole in the block.5. When the valve lifter is in position in the block, use Tool (C) to push the valve lifter off of Tool (C). 6. Use Tool (E) to turn the crankshaft to make sure there is not pressure on the push rods and rocker arms.7. Put push rod (3) in position in the block. Use Tool (D) to move rocker arm (4) away from the push rod far enough to put push rod (3) in position under the rocker arm.End By:a. install valve cover
Any time the valve lifter is removed from the machine, a new spring guide must be installed on the valve lifter.1. Install spring guide (1) on valve lifter (2). 2. Put the valve lifter in position on Tool (A) as shown. Make sure spring guide (1) is in position in the groove (slot) in the valve lifter as shown. 3. Use a soft hammer to install Tool (B) over spring guide (1). Make sure the groove in Tool (B) is in alignment with spring guide (1). 4. Put clean engine oil on valve lifter (2). Use Tool (B) to install the valve lifter in the engine block. Make sure the end of the spring guide is in alignment with the small hole in the block.5. When the valve lifter is in position in the block, use Tool (C) to push the valve lifter off of Tool (C). 6. Use Tool (E) to turn the crankshaft to make sure there is not pressure on the push rods and rocker arms.7. Put push rod (3) in position in the block. Use Tool (D) to move rocker arm (4) away from the push rod far enough to put push rod (3) in position under the rocker arm.End By:a. install valve cover