Information injection-pump assembly
ZEXEL
106891-1310
1068911310
ISUZU
1156025911
1156025911

Rating:
Service parts 106891-1310 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:
106891-1310
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106891-1310
1068911310
ISUZU
1156025911
1156025911
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
7.3
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
87.8
86.3
89.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
77.9
75.9
79.9
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.3
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
106.5
102.5
110.5
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.7
7.4
10
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1150
Advance angle
deg.
5
4.5
5.5
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Damper spring setting
(3)Variable speed specification: idling adjustment
(4)Main spring setting
(5)Set idle sub-spring
----------
----------
----------
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(8deg)+-5deg b=(25deg)+-5deg
----------
----------
a=(8deg)+-5deg b=(25deg)+-5deg
0000000901

F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=27.5deg+-3deg
----------
----------
a=10deg+-5deg b=27.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
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
(4)-
----------
aa=10deg
----------
a=(180deg)
----------
aa=10deg
----------
a=(180deg)
Information:
Electronic Controls
The electronic controller consists of two main components: the Electronic Control Module (ECM) and the Personality Module. The ECM is the computer which controls the PEEC engine. The Personality Module is the software which controls how the computer behaves. The two must be used together: neither can do anything by itself.Rack Controls
The rack mechanism on a PEEC III engine is very similar to a mechanical 3406B engine. The fuel injection pump is nearly identical; the rack is moved by a servo valve which receives oil pressure from the fuel injection pump. However, the PEEC III servo spool is moved by a solenoid or (BTM) rather than by a linkage controlled by flyweights and springs.PEEC III comes up with a "desired rpm" based on the throttle position, vehicle speed, customer specified parameters, and certain diagnostic codes. The PEEC III governor tries to maintain the desired rpm by sensing actual engine speed using the engine speed sensor, then controlling the rack to achieve the desired rpm. To move the rack, PEEC III adjusts the voltage to the rack solenoid (BTM) to increase rack. More voltage results in more rack. PEEC III knows how far the rack went by reading the rack position sensor. PEEC III increases the voltage to the rack solenoid until it senses the rack is in the desired position. PEEC III sets certain limits on rack motion. "FRC Rack" is a rack limit based on fuel-air ratio control, for emissions purposes. It works similar to a mechanical engine FRC; when PEEC III senses a higher boost pressure (more air into cylinder), it increases the FRC Rack limit, which allows more fuel into the cylinder. "Rated Rack" is a rack limit based on horsepower of the engine. It is similar to the rack stops and torque springs on a mechanical engine. It provides horsepower and torque curves for a specific engine family and rating. All of these limits are programmed by the factory into the personality module.Timing Advance Controls
The timing advance mechanism is the same as the 3406B mechanical engine, except the Timing solenoid (BTM), instead of the flyweights, controls timing advance. PEEC III adjusts voltage to the timing solenoid to change timing advance. More voltage results in more timing advance. PEEC III knows how much advance was achieved by reading the timing position sensor. PEEC III simply increases voltage to the timing solenoid until it senses that the timing advance is in the desired position. Programmable Parameters
Certain parameters that affect PEEC III 3406B Diesel Engine operation may be changed with electronic service tools (either the ECAP or DDT). The parameters are stored in the ECM, and are protected from unauthorized changes by passwords.These parameters are either "System Configuration Parameters" or "Customer Parameters". System Configuration Parameters are those that effect horsepower family or emissions. Customer Parameters are those that affect cruise control, vehicle speed limits, progressive shifting, horsepower rating within a family, and PTO operation.Some parameters may affect engine operation in ways a driver does not expect
The electronic controller consists of two main components: the Electronic Control Module (ECM) and the Personality Module. The ECM is the computer which controls the PEEC engine. The Personality Module is the software which controls how the computer behaves. The two must be used together: neither can do anything by itself.Rack Controls
The rack mechanism on a PEEC III engine is very similar to a mechanical 3406B engine. The fuel injection pump is nearly identical; the rack is moved by a servo valve which receives oil pressure from the fuel injection pump. However, the PEEC III servo spool is moved by a solenoid or (BTM) rather than by a linkage controlled by flyweights and springs.PEEC III comes up with a "desired rpm" based on the throttle position, vehicle speed, customer specified parameters, and certain diagnostic codes. The PEEC III governor tries to maintain the desired rpm by sensing actual engine speed using the engine speed sensor, then controlling the rack to achieve the desired rpm. To move the rack, PEEC III adjusts the voltage to the rack solenoid (BTM) to increase rack. More voltage results in more rack. PEEC III knows how far the rack went by reading the rack position sensor. PEEC III increases the voltage to the rack solenoid until it senses the rack is in the desired position. PEEC III sets certain limits on rack motion. "FRC Rack" is a rack limit based on fuel-air ratio control, for emissions purposes. It works similar to a mechanical engine FRC; when PEEC III senses a higher boost pressure (more air into cylinder), it increases the FRC Rack limit, which allows more fuel into the cylinder. "Rated Rack" is a rack limit based on horsepower of the engine. It is similar to the rack stops and torque springs on a mechanical engine. It provides horsepower and torque curves for a specific engine family and rating. All of these limits are programmed by the factory into the personality module.Timing Advance Controls
The timing advance mechanism is the same as the 3406B mechanical engine, except the Timing solenoid (BTM), instead of the flyweights, controls timing advance. PEEC III adjusts voltage to the timing solenoid to change timing advance. More voltage results in more timing advance. PEEC III knows how much advance was achieved by reading the timing position sensor. PEEC III simply increases voltage to the timing solenoid until it senses that the timing advance is in the desired position. Programmable Parameters
Certain parameters that affect PEEC III 3406B Diesel Engine operation may be changed with electronic service tools (either the ECAP or DDT). The parameters are stored in the ECM, and are protected from unauthorized changes by passwords.These parameters are either "System Configuration Parameters" or "Customer Parameters". System Configuration Parameters are those that effect horsepower family or emissions. Customer Parameters are those that affect cruise control, vehicle speed limits, progressive shifting, horsepower rating within a family, and PTO operation.Some parameters may affect engine operation in ways a driver does not expect