Rating:
Information injection-pump assembly
ZEXEL
106871-1132
1068711132
ISUZU
1156030321
1156030321
Cross reference number
ZEXEL
106871-1132
1068711132
ISUZU
1156030321
1156030321
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
1-8-7-3-
6-5-4-2
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. 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
-
Rack position
10.7
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
121
119.4
122.6
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
6.5+-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(10.7)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
121
120
122
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
122
118
126
Fixing the lever
*
Timer adjustment
Pump speed
r/min
[N1+50]-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N1
Advance angle
deg.
0
0
0
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
2
1.5
2.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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=AC89
----------
----------
T1=AC89
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
----------
aa=55mm
----------
a=20deg+-5deg b=35deg+-3deg
----------
aa=55mm
----------
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 bb=1.5+-0.3mm
----------
a=20deg+-5deg b=43deg+-5deg
----------
aa=40mm bb=0r/min bb=1.5+-0.3mm
----------
a=20deg+-5deg b=43deg+-5deg
0000001501 AIR CYLINDER
1. (1) Set the speed lever to idle.
(2)Screw in air cylinder (A)
(3)Set the clearance from the speed lever (B) at approximately L.
----------
L=(1)mm
----------
----------
L=(1)mm
----------
0000001601 TAMPER PROOF
SW:Inner hexagonal SW14
(F): Apply thread lock adhesive .
(G): Full tamper proof
(H): Full boost (Full rack)
(I): 0 boost
1. Mount (C) and (D) after adjusting the boost compensator.
2. Back off the load lever set screw L1 from the end face of the governor housing..
3. Apply boost pressure and set the full load at tamper set position point aa to obtain N1, Q1 and Ra using the screw C.
4. Fix using the nut (D).
5. Next, after adjusting the stop lever, confirm the point aa.
6. Reset the load lever to the full boost rack.
7. After completion of setting, seal using the plug (E).
----------
L1=6+1mm N1=800r/min R1=R1(10.7)+0.4mm Q=103+-1.6mm3/st aa=D
----------
T1=53.9~73.5N-m(5.5~7.5Kgf-m) T2=2.94~4.41N-m(0.3~0.45Kgf-m)
----------
L1=6+1mm N1=800r/min R1=R1(10.7)+0.4mm Q=103+-1.6mm3/st aa=D
----------
T1=53.9~73.5N-m(5.5~7.5Kgf-m) T2=2.94~4.41N-m(0.3~0.45Kgf-m)
0000001701 TAMPER PROOF
(A): Rotation tamper proof
(B): Full-speed setting
1. Back off the full-speed set bolt.
2. Confirm that the tamper setting position is N1, R1, Q1.
3. At that time, record the angle of the speed lever.
4. After confirming the above setting, set full speed.
----------
N1=(1420)r/min R1=5.7+-0.1mm Q1=-
----------
----------
N1=(1420)r/min R1=5.7+-0.1mm Q1=-
----------
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=10deg
----------
a=(170deg)
----------
aa=10deg
----------
a=(170deg)