Information injection-pump assembly
ZEXEL
106891-1335
1068911335
ISUZU
1156027683
1156027683
Rating:
Service parts 106891-1335 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:
106891-1335
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106891-1335
1068911335
ISUZU
1156027683
1156027683
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)
134424-4320
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
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
800+-30
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
870
Advance angle
deg.
2
1.7
2.3
Timer adjustment_05
Pump speed
r/min
1050
Advance angle
deg.
3.5
3
4
Timer adjustment_06
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
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
----------
----------
----------
----------
Speed control lever angle
F:Full speed
----------
----------
a=7deg+-5deg
----------
----------
a=7deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=34deg+-3deg
----------
----------
a=10deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=25mm
----------
a=64deg+-5deg b=51deg+-5deg
----------
aa=25mm
----------
a=64deg+-5deg b=51deg+-5deg
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. Install the turbocharger on tool (A) as shown.2. Put alignment marks on three housings of the turbocharger for correct alignment during assembly. Loosen clamp (2), and remove the clamp and housing (1) from housing assembly (3). 3. Loosen clamp (4), and remove housing assembly (3) from housing (5). 4. Put the cartridge group in position in tool (B) as shown.
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
5. Use a 5S9566 Sliding T-Wrench and a universal socket (6) to remove the nut that holds the compressor wheel to the wheel assembly.6. Remove compressor wheel (7) and the shims from wheel assembly (8).7. Remove housing assembly (3) from wheel assembly (8). 8. Remove ring (9) and backplate (10) from wheel assembly (8). 9. Use tool (C), and remove snap ring (11) from housing assembly (3). 10. Remove insert (12) and sleeve (13) from housing assembly (3). 11. Remove ring (14) from sleeve (13). 12. Remove two screws (15) and deflector (16) from housing assembly (3). 13. Remove ring (18) and bearing assembly (17) from the housing assembly. 14. Remove sleeve (19) and ring (20) from the housing assembly. 15. Remove O-ring seal (23) from the housing assembly.16. Use tool (D), and remove snap ring (22) from the housing assembly.17. Remove bearing (21). Remove the snap ring behind the bearing with tool (D). 18. Use tool (D), and remove snap ring (25) from the housing assembly.19. Remove bearing (24). Remove the snap ring behind the bearing with tool (D).20. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction, Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, pour clean engine oil into the oil inlet of the turbocharger.
Make sure that the snap rings that hold bearings (24) and (21) in position in housing assembly (3) are installed with the round edge of the outside diameter toward the bearing.
2. Install the snap ring behind bearing (24) with tool (D).3. Install bearing (24) in housing assembly (3).4. Use tool (D), and install snap ring (25) in the housing assembly. 5. Install the snap ring behind bearing (21) with tool (D).6. Install bearing (21) in the housing assembly.7. Use tool (D), and install snap ring (22) in the housing assembly. 8. Put wheel assembly (8) in position on tool (B) as shown.9. Put backplate (10) in position on the wheel assembly. Put 6V2055 High Vacuum Grease
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
5. Use a 5S9566 Sliding T-Wrench and a universal socket (6) to remove the nut that holds the compressor wheel to the wheel assembly.6. Remove compressor wheel (7) and the shims from wheel assembly (8).7. Remove housing assembly (3) from wheel assembly (8). 8. Remove ring (9) and backplate (10) from wheel assembly (8). 9. Use tool (C), and remove snap ring (11) from housing assembly (3). 10. Remove insert (12) and sleeve (13) from housing assembly (3). 11. Remove ring (14) from sleeve (13). 12. Remove two screws (15) and deflector (16) from housing assembly (3). 13. Remove ring (18) and bearing assembly (17) from the housing assembly. 14. Remove sleeve (19) and ring (20) from the housing assembly. 15. Remove O-ring seal (23) from the housing assembly.16. Use tool (D), and remove snap ring (22) from the housing assembly.17. Remove bearing (21). Remove the snap ring behind the bearing with tool (D). 18. Use tool (D), and remove snap ring (25) from the housing assembly.19. Remove bearing (24). Remove the snap ring behind the bearing with tool (D).20. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction, Form No. SMHS6854 for Turbocharger Reconditioning. Also see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, pour clean engine oil into the oil inlet of the turbocharger.
Make sure that the snap rings that hold bearings (24) and (21) in position in housing assembly (3) are installed with the round edge of the outside diameter toward the bearing.
2. Install the snap ring behind bearing (24) with tool (D).3. Install bearing (24) in housing assembly (3).4. Use tool (D), and install snap ring (25) in the housing assembly. 5. Install the snap ring behind bearing (21) with tool (D).6. Install bearing (21) in the housing assembly.7. Use tool (D), and install snap ring (22) in the housing assembly. 8. Put wheel assembly (8) in position on tool (B) as shown.9. Put backplate (10) in position on the wheel assembly. Put 6V2055 High Vacuum Grease