Information injection-pump assembly
ZEXEL
106891-1253
1068911253
ISUZU
1156025255
1156025255
Rating:
Service parts 106891-1253 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-204-1
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106891-1253
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106891-1253
1068911253
ISUZU
1156025255
1156025255
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 (drive side)
134424-4020
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
4.2
4.17
4.23
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
A
Rack position
8.5
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
110
108.5
111.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
111.6
109.6
113.6
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
117.4
115.4
119.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.9+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.8
7.5
10.1
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600--
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.3
Load
4/4
Timer adjustment_03
Pump speed
r/min
800+-30
Advance angle
deg.
2
1.5
2.5
Load
4/4
Timer adjustment_04
Pump speed
r/min
900
Advance angle
deg.
2
1.5
2.5
Load
3/4
Timer adjustment_05
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Damper spring setting
(5)Variable speed specification: idling adjustment
(6)Main spring setting
----------
RT=0.8 TH=2mm
----------
----------
RT=0.8 TH=2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=150mm
----------
a=7deg+-5deg b=(15deg)+-5deg
----------
aa=150mm
----------
a=7deg+-5deg b=(15deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=10deg+-5deg b=34deg+-3deg
----------
aa=35mm
----------
a=10deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
0000001201
(1)Variable speed specification
(2)Minimum - maximum speed specification
(3)Lever angle = c or less
----------
----------
a=13deg+-5deg b=(20deg) c=26deg
----------
----------
a=13deg+-5deg b=(20deg) c=26deg
0000001501 LEVER
2-stage changeover lever adjustment
(A) Speed lever
(B) Load lever
(C) 2-stage changeover lever
(D) Link
(E) Bolt
1. Minimum-maximum speed specification adjustment (when running)
(1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper.
(2)In this condition, the load lever is held in the idle position.
(3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L.
(4)Lock using the nut.
2. Variable speed specification adjustment (at operation)
(1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.)
(2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------
----------
L=1~2mm
----------
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 (set timing)
(4)-
----------
aa=8deg
----------
a=(180deg)
----------
aa=8deg
----------
a=(180deg)
Information:
(1) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in)(2) Bore diameter in cylinder block for the cylinder liners ... 136.00 0.03 mm (5.354 .001 in)(3) Distance dowels extend past end surface of cylinder block ... 8.0 0.5 mm (.31 .02 in) (4) Spacer block.(5) Height of dowels above top surface of spacer block and cylinder block ... 8.00 0.03 mm (.315 .001 in)(6) Cylinder Liner. Make reference to the procedure for checking Cylinder Liner Projection in Testing And Adjusting Section of Service Manual Form No. SENR5108. Cylinder liner projection above the top surface of the spacer block must be ... 0.12 0.08 mm (.005 .003 in) Apply 7M7260 Liquid Gasket as required to cylinder liner shoulder and cylinder block face joint of all liners. (7) Depth plug is to be installed (from end surface of cylinder block to top of plug) ... 1.25 0.25 mm (.049 .010 in)(8) Diameter of camshaft bores ... 75.000 0.025 mm (2.9530 .0010 in)(9) Oil cooling jet assembly. Tighten bolt that holds oil cooling jet to ... 25 7 N m (18 5 1b ft)(10) Width of main bearing cap ... 175.00 0.02 mm (6.8898 .0008 in) Width in cylinder block for main bearing cap ... 175.000 0.018 mm (6.8898 .0007 in)(11) Distance from centerline of crankshaft bore to top surface of cylinder block ... 265.0 mm (10.43 in)The flatness across the top contact surface of the block must be within 0.05 mm (.002 in) for any 150 mm (5.9 in) section of the surface.(12) Distance from centerline of crankshaft to bottom surface of cylinder block ... 120.0 mm (4.72 in)(13) Main bearing cap bolts. Install as follows: Main bearing caps shall be assembled with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.Main bearing cap bolts to be lubricated on threads and washer face with SAE 30 oil or molylube. Tighten bolts to 95 5 N m (70 4 lb ft) plus 90 5° additional turn prior to machining. Tighten bolts simultaneously or tighten both bolts to 95 N m (70 lb ft) before turning the additional 90°.(14) Bore in cylinder block for seven main bearings ... 108.000 0.013 mm (4.2520 .0005 in) All main bearing bore measurements are to be made before caps are disassembled.