Information injection-pump assembly
ZEXEL
106891-1370
1068911370
ISUZU
1156027720
1156027720
Rating:
Cross reference number
ZEXEL
106891-1370
1068911370
ISUZU
1156027720
1156027720
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
(3)Variable speed specification: idling adjustment
(4)Main spring setting
----------
----------
----------
----------
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.
(1)Use the hole at R = aa
----------
aa=25mm
----------
a=51deg+-5deg b=64deg+-5deg
----------
aa=25mm
----------
a=51deg+-5deg b=64deg+-5deg
0000001201
(1)Variable speed specification
(2)Minimum - maximum speed specification
(3)Lever angle = c or less
(4)Use the hole at R = aa
----------
aa=130mm
----------
a=13deg+-5deg b=(20deg) c=26deg
----------
aa=130mm
----------
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:
Do not disconnect any air lines until the air pressure is zero.
1. Loosen the bleed valves and release the air pressure in the air tanks.2. Drain the oil from the oil pan. 3. Remove two short bolts (1) and two longer bolts (3) from manifold (2) and the BrakeSaver housing. Remove manifold (2). Remove the O-ring seals from the manifold. 4. Remove oil temperature sensing unit (4) from the BrakeSaver control valve.5. Disconnect air line (5) and hose assembly (6) from the BrakeSaver control valve. 6. Remove bolt (7) and retainer (8) that hold the oil lines in the BrakeSaver control valve. 7. Disconnect oil lines (9) and (10) from the oil cooler. Remove oil lines (9) and (10) from the BrakeSaver control valve. 8. Remove bolts (12) and BrakeSaver control valve (11) from under the oil pan. The weight is 22 kg (48 lb.).9. Remove elbow (13) from the BrakeSaver control valve. Remove the O-ring seals. The following steps are for installation of the BrakeSaver control valve.10. Inspect the O-ring seals for damage, and make replacements if needed. Put clean engine oil on the O-ring seals.11. Install the O-ring seals and elbow (13) on the BrakeSaver control valve.12. Make sure the O-ring seals are in position on the face of the BrakeSaver control valve. Put BrakeSaver control valve (11) in position under the oil pan. Install bolts (12) that hold the BrakeSaver control valve to the oil pan.13. Install oil temperature sensing unit (4) in the BrakeSaver control valve.14. Connect air line (5) and hose assembly (6) to the BrakeSaver control valve.15. Install the O-ring seals on manifold (2). Install manifold (2) in the BrakeSaver control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.16. Make sure the O-ring seals are in place on the oil lines, and install oil lines (9) and (10).17. Install retainer (8) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Pipe Sealant With Teflon on the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb.ft.).18. Fill the engine with oil to the correct level. See the Maintenance Manual.Disassemble & Assemble BrakeSaver Control Valve
Start By:a. remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.
Covers (3) and (4) hold a spring under compression. To prevent possible personal injury from flying parts, hold covers (3) and (4) when the bolts are removed.
2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the O-ring seals and sleeve (5). 7. Remove bolt (11), plate