Information injection-pump assembly
ZEXEL
106971-1064
1069711064
ISUZU
1156029564
1156029564
Rating:
Service parts 106971-1064 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:
106971-1064
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106971-1064
1069711064
ISUZU
1156029564
1156029564
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
1-8-7-6-
5-4-3-10
-9-2
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. 27 26.75 27.25
Cal 1-8 deg. 27 26.75 27.25
Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25
Cal 1-7 deg. 72 71.75 72.25
Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25
Cal 1-6 deg. 99 98.75 99.25
Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25
Cal 1-5 deg. 144 143.75 144.25
Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25
Cal 1-4 deg. 171 170.75 171.25
Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25
Cal 1-3 deg. 216 215.75 216.25
Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25
Cal 1-10 deg. 243 242.75 243.25
Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25
Cal 1-9 deg. 288 287.75 288.25
Difference between angles 9
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
11.9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
141
139.4
142.6
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(11.9)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
141
140
142
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.25
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
140.5
136.5
144.5
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=AD38
----------
----------
T1=AD38
----------
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=22.5deg+-5deg b=(30deg)+-3deg
----------
aa=42.5mm
----------
a=22.5deg+-5deg b=(30deg)+-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=790r/min Ra=R1(11.9)+0.2mm Vist=1.53+-0.14V
----------
----------
V1=5+-0.01V N1=790r/min Ra=R1(11.9)+0.2mm Vist=1.53+-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:
Removal of Fuel System
To prevent dust from entering the fuel system, cover all openings in the injection pump, nozzle inlet connectors and injection pipes.
Removal of Fuel Injection Pump
Removal of fuel injection pump (1)
Removal of fuel injection pump (2)(1) Check the alignment marks stamped on the flange of the fuel injection pump and the pump mounting flange.(2) Remove the front cover from the engine.(3) Place alignment marked on the fuel injection pump gear and idler gear.(4) Unscrew the mounting bolts from the fuel injection pump flange, and remove the fuel injection pump together with the flange from the front plate. (a) After the fuel injection pump is removed, do not turn the engine.(b) When removing the pump gear, loosen the gear retaining nut while the pump is mounted on the engine.Disassembly, Inspection and Reassembly of Fuel System
Disassembly of Fuel Injection Nozzles
Inspection of Fuel Injection Nozzles
Inspection of fuel injection nozzle valve openingCheck each fuel injection nozzle for the following, and if defects are found, repair or replace the fuel injection nozzle.(1) Inspection of injection start pressure(a) Install each fuel injection nozzle on the nozzle tester, and move the handle up and down to release air.(b) Operate the handle of the tester at a rate of about 1 stroke per second, and read the indication on the pressure gage. The indication rises slowly, and the indicator oscillates during spraying. To obtain the injection start pressure value, read the indication when the indicator starts to oscillate.(c) If the injection start pressure deviates significantly from the standard value, disassemble the fuel injection nozzle, and make an adjustment by changing the washer thickness.
Replacement of fuel injection nozzle tip 0.1 mm [0.0039 in.] thickness of shims will change the injection pressure 0.98 Mpa (10 kgf/cm2 [142 psi]. The shims are available in 10 different thickness from 1.25 to 1.70 mm [0.0492 to 0.0669 in.] increment of 0.05 mm [0.0020 in.]
Never tap the tip of the nozzle tip when removing the nozzle tip.
(2) Inspection f fuel injection nozzle spray pattern
Inspection of spray pattern of fuel injection nozzle(a) When inspecting each fuel injection nozzle with the nozzle tester, also check the nozzle for clogs, spray pattern and leakage.(b) Make sure that the fuel is sprayed straight from the nozzle when the handle of the tester is operated at a rate of about 1 stroke per second.(3) Cleaning and replacement of faulty nozzles
Cleaning of fuel injection nozzle tip(a) Loosen the nozzle retaining nut, remove the nozzle tip, and clean the needle valve and body.
Never tap the tip of the nozzle tip when removing the nozzle tip.
(b) Use a fresh cleaning solution to clean the needle valve and body. after cleaning, assemble the needle valve and body in clean diesel fuel. The needle valve and body are precision finished. Handle them carefully, and do not change the combination of parts.(c) Tighten the nozzle retaining nut on the nozzle tip to the specified torque.(d) If the spray pattern is still not acceptable after adjustment and cleaning, replace the nozzle tip.
To prevent dust from entering the fuel system, cover all openings in the injection pump, nozzle inlet connectors and injection pipes.
Removal of Fuel Injection Pump
Removal of fuel injection pump (1)
Removal of fuel injection pump (2)(1) Check the alignment marks stamped on the flange of the fuel injection pump and the pump mounting flange.(2) Remove the front cover from the engine.(3) Place alignment marked on the fuel injection pump gear and idler gear.(4) Unscrew the mounting bolts from the fuel injection pump flange, and remove the fuel injection pump together with the flange from the front plate. (a) After the fuel injection pump is removed, do not turn the engine.(b) When removing the pump gear, loosen the gear retaining nut while the pump is mounted on the engine.Disassembly, Inspection and Reassembly of Fuel System
Disassembly of Fuel Injection Nozzles
Inspection of Fuel Injection Nozzles
Inspection of fuel injection nozzle valve openingCheck each fuel injection nozzle for the following, and if defects are found, repair or replace the fuel injection nozzle.(1) Inspection of injection start pressure(a) Install each fuel injection nozzle on the nozzle tester, and move the handle up and down to release air.(b) Operate the handle of the tester at a rate of about 1 stroke per second, and read the indication on the pressure gage. The indication rises slowly, and the indicator oscillates during spraying. To obtain the injection start pressure value, read the indication when the indicator starts to oscillate.(c) If the injection start pressure deviates significantly from the standard value, disassemble the fuel injection nozzle, and make an adjustment by changing the washer thickness.
Replacement of fuel injection nozzle tip 0.1 mm [0.0039 in.] thickness of shims will change the injection pressure 0.98 Mpa (10 kgf/cm2 [142 psi]. The shims are available in 10 different thickness from 1.25 to 1.70 mm [0.0492 to 0.0669 in.] increment of 0.05 mm [0.0020 in.]
Never tap the tip of the nozzle tip when removing the nozzle tip.
(2) Inspection f fuel injection nozzle spray pattern
Inspection of spray pattern of fuel injection nozzle(a) When inspecting each fuel injection nozzle with the nozzle tester, also check the nozzle for clogs, spray pattern and leakage.(b) Make sure that the fuel is sprayed straight from the nozzle when the handle of the tester is operated at a rate of about 1 stroke per second.(3) Cleaning and replacement of faulty nozzles
Cleaning of fuel injection nozzle tip(a) Loosen the nozzle retaining nut, remove the nozzle tip, and clean the needle valve and body.
Never tap the tip of the nozzle tip when removing the nozzle tip.
(b) Use a fresh cleaning solution to clean the needle valve and body. after cleaning, assemble the needle valve and body in clean diesel fuel. The needle valve and body are precision finished. Handle them carefully, and do not change the combination of parts.(c) Tighten the nozzle retaining nut on the nozzle tip to the specified torque.(d) If the spray pattern is still not acceptable after adjustment and cleaning, replace the nozzle tip.