Information injection-pump assembly
ZEXEL
106991-1292
1069911292
ISUZU
1156027621
1156027621

Rating:
Service parts 106991-1292 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:
106991-1292
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1292
1069911292
ISUZU
1156027621
1156027621
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
1-8-7-6-
5-4-3-10
-9-2
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. 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
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:
Safety is everyone's business and is basically the use of good common sense. A general guide of safety precautions are given below, but each installation has its own peculiarities which cannot always be predicted and covered by established rules. Past experience and common sense are needed for the necessary safety measures. Attention to safety will help avoid serious accidents. Be alert. Watch for hazards. Use preventive measures. Correct deficiencies immediately.The following safety precautions are a general guide to safe operation:1. To prevent personal injury, install guards over all exposed rotating parts.2. To prevent hearing damage, wear ear protective devices if working inside an enclosed engine room with engine running.3. To prevent head injury, wear safety hat when working in the area of overhead equipment.4. Wear safety glasses and shoes as required. 5. Do not wear loose clothing whenever working around engines or machinery.6. Wipe up spilled oil, fuel or coolant.7. Keep batteries in a well ventilated area. Do not smoke around batteries. Hydrogen gas, which is present in the area of the batteries, is highly explosive.8. Provide adequate and safe waste oil disposal.9. Store oily rags in fireproof containers. Don't leave rags on engine.
When using pressure air, wear safety glasses and protective clothing. Maximum air pressure, used for cleaning, must be below 30 PSI (2 kg/cm2).
10. Remove all tools, electrical cords and other loose items from the engine before starting.11. Disconnect and tape the battery ground lead before working on an engine to prevent accidental starting. Be sure an automatic start-stop system cannot operate and start the engine while working on it.12. Do not attempt repairs you do not understand. Follow instructions.13. Stop engine before adjusting or repairing engine or driven equipment.14. Remove radiator cap slowly. Cooling systems can be pressurized and hot fluid will flash to steam as pressure is removed.15. Never start an engine with the governor linkage disconnected.16. Replace or repair broken or damaged equipment. Use proper tools.17. Do not smoke while refueling. Observe NO SMOKING signs.18. Never store flammable liquids near the engine.19. All electrical equipment must be grounded according to local building codes.20. Check all connections periodically for tightness and insulation.21. Insulate all connections and disconnected wires.22. Do not use carbon tetrachloride fire extinguishers. Fumes are toxic and the liquid has a deteriorating effect on insulation. 23. Do not touch the heat sink on the generator regulator when the generator is running. It is electrically "hot".24. Do not work on electrically "hot" equipment.25. Always disconnect the engine starter circuit when working on the generator.26. Hot engine oil can cause burns when drained. Allow the oil to cool below 140°F or provide protection when draining the hot oil.27. Never remove a plug to check pressure with the engine running. Shut down the engine and assure there is no pressure before removing plug.28. When starting an engine after repair, make provisions for shutting off air supply in case there is an overspeed on start up.29. Never look into an open cylinder port and turn over
When using pressure air, wear safety glasses and protective clothing. Maximum air pressure, used for cleaning, must be below 30 PSI (2 kg/cm2).
10. Remove all tools, electrical cords and other loose items from the engine before starting.11. Disconnect and tape the battery ground lead before working on an engine to prevent accidental starting. Be sure an automatic start-stop system cannot operate and start the engine while working on it.12. Do not attempt repairs you do not understand. Follow instructions.13. Stop engine before adjusting or repairing engine or driven equipment.14. Remove radiator cap slowly. Cooling systems can be pressurized and hot fluid will flash to steam as pressure is removed.15. Never start an engine with the governor linkage disconnected.16. Replace or repair broken or damaged equipment. Use proper tools.17. Do not smoke while refueling. Observe NO SMOKING signs.18. Never store flammable liquids near the engine.19. All electrical equipment must be grounded according to local building codes.20. Check all connections periodically for tightness and insulation.21. Insulate all connections and disconnected wires.22. Do not use carbon tetrachloride fire extinguishers. Fumes are toxic and the liquid has a deteriorating effect on insulation. 23. Do not touch the heat sink on the generator regulator when the generator is running. It is electrically "hot".24. Do not work on electrically "hot" equipment.25. Always disconnect the engine starter circuit when working on the generator.26. Hot engine oil can cause burns when drained. Allow the oil to cool below 140°F or provide protection when draining the hot oil.27. Never remove a plug to check pressure with the engine running. Shut down the engine and assure there is no pressure before removing plug.28. When starting an engine after repair, make provisions for shutting off air supply in case there is an overspeed on start up.29. Never look into an open cylinder port and turn over