Information injection-pump assembly
ZEXEL
106971-1071
1069711071
ISUZU
1156029541
1156029541
Rating:
Service parts 106971-1071 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:
106971-1071
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106971-1071
1069711071
ISUZU
1156029541
1156029541
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
1-4-9-8-
5-2-11-1
0-3-6-7-
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 1-4 deg. 15 14.75 15.25
Cal 1-4 deg. 15 14.75 15.25
Difference between angles 2
Cal 1-9 deg. 60 59.75 60.25
Cal 1-9 deg. 60 59.75 60.25
Difference between angles 3
Cal 1-8 deg. 75 74.75 75.25
Cal 1-8 deg. 75 74.75 75.25
Difference between angles 4
Cal 1-5 deg. 120 119.75 120.25
Cal 1-5 deg. 120 119.75 120.25
Difference between angles 5
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 6
Cal 1-11 deg. 180 179.75 180.25
Cal 1-11 deg. 180 179.75 180.25
Difference between angles 7
Cal 1-10 deg. 195 194.75 195.25
Cal 1-10 deg. 195 194.75 195.25
Difference between angles 8
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 9
Cal 1-6 deg. 255 254.75 255.25
Cal 1-6 deg. 255 254.75 255.25
Difference between angles 10
Cal 1-7 deg. 300 299.75 300.25
Cal 1-7 deg. 300 299.75 300.25
Difference between angles 11
Cal 1-12 deg. 315 314.75 315.25
Cal 1-12 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
12
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
142
140.4
143.6
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(12)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
142
141
143
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
138
134
142
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=AC13
----------
----------
T1=AC13
----------
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=(8)deg 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=(8)deg 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 hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=42.5mm
----------
a=20deg+-5deg b=(35deg)+-3deg
----------
aa=42.5mm
----------
a=20deg+-5deg b=(35deg)+-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=750r/min Ra=R1(12)mm Vist=1.55+-0.14V
----------
----------
V1=5+-0.01V N1=750r/min Ra=R1(12)mm Vist=1.55+-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=(170deg)
----------
aa=4deg
----------
a=(170deg)
Information:
Inspection of adjustment voltage (a) Disconnect the cable from the positive (+) terminal of the battery, and connect an ammeter between the terminal and cable.(b) Connect a voltmeter between terminal L and ground.(c) Make sure that the voltmeter indicates "0" when the starter switch is turned off. Make sure that the voltmeter indicates a voltage level significantly lower than the battery voltage when the starter switch is turned on (without starting the engine).(d) Short-circuit the terminal of the ammeter, and start the engine.(e) Read the indication (adjustment voltage) on the voltmeter with the ammeter indicating 5A or lower, the engine operating at 1500 to 2500 min-1, and the lamp switches turned off.(3) Inspection of output (unit with integrated IC regulator)
Wiring for output test (a) Disconnect the grounding cable from the battery.(b) Disconnect the wire from terminal B of the alternator, and connect an ammeter, then connect a voltmeter between B and ground.(c) Reconnect the grounding cable to the battery.(d) Start the engine.(e) Immediately after the engine starts, turn on all load devices such as lamps.(f) Increase the engine speed, and read the maximum current at the specified alternator rotation speed when the voltmeter indicates 27.0 V. If the measured value conforms to the standard value, the alternator is normal.Disassembly of Alternator
(1) Separation of front bracket from stator coreInsert the tip of a slotted screwdriver into the gap between the stator core and front bracket, and pry open.
Separation of front bracket from stator core
Do not insert the screwdriver too far into the assembly to prevent damaging the stator core.
(2) Removal of the pulley
Removal of pulley(a) After wrapping the rotor with a cloth for protection and holding it with a vice, unscrew the pulley nut, then remove the pulley and spacer.(b) Remove the rotor from the front bracket.(3) Removal of stator core and rectifier
Removal of stator core(a) Disconnect the lead wires between the stator core and the rectifier at the soldered sections, and remove the stator core.
Melt the soldered sections as quickly as possible. Prolonged heating cam damage the diodes.
(b) Unscrew the rectifier mounting screws, and dismount the rectifier.Inspection and Repair of Alternator
(1) Inspection of diodes
Inspection of diodesConduct a continuity test with each diode in the rectifier.(a) Using a tester, check continuity between each diode lead terminal and its case. If the resistance value is large in one direction and small in the opposite direction, the diode is normal.(b) If the resistance measurements are the same in both directions, replace the rectifier. Be sure to check all diodes.(2) Inspection of field coil
Field coil continuity test(a) Check continuity between snap rings. If there is no continuity, there is an open-circuit; replace the field coil.
Field coil grounding test(b) Check