Information injection-pump assembly
ZEXEL
106671-1367
1066711367
ISUZU
1156021401
1156021401
Rating:
Cross reference number
ZEXEL
106671-1367
1066711367
ISUZU
1156021401
1156021401
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 opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.7
3.67
3.73
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
131.5
129.5
133.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.7
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
119.8
117.8
121.8
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_03
Adjusting point
C
Rack position
5.4+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
8.2
5
11.4
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
85
85
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
7
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
8.5
Boost pressure
kPa
17.3
17.3
17.3
Boost pressure
mmHg
130
130
130
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Excess fuel setting for starting: SXL
(2)Boost compensator stroke: BCL
(3)Damper spring setting: DL
----------
SXL=8.6+0.2mm BCL=1.5+-0.1mm DL=4.4-0.5mm
----------
----------
SXL=8.6+0.2mm BCL=1.5+-0.1mm DL=4.4-0.5mm
----------
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=(5.5)deg t1=2--sec. t2=2--sec.
----------
N1=800++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.5+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(5.5)deg t1=2--sec. t2=2--sec.
----------
N1=800++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.5+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=8deg+-5deg
----------
----------
a=8deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=35mm
----------
a=15deg+-5deg b=35deg+-3deg
----------
aa=35mm
----------
a=15deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=37deg+-5deg b=73deg+-5deg
----------
----------
a=37deg+-5deg b=73deg+-5deg
0000001501 RACK SENSOR
V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1= 5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1= 5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
White Smoke
Recommended Procedure
1. Cold Outside Temperatures ... When the air outside is cold, the cylinder temperature is cooler. Not all the fuel will burn in the cylinders. The fuel which does not burn comes out the exhaust as white smoke. White smoke is normal in cold temperatures until the engine operates long enough to become warm. There will be less white smoke if No. 1 diesel fuel is used.2. Long Idle Periods ... When an engine runs at idle speed for a long period of time, the cylinders cool and all of the fuel does not burn. Do not idle an engine for a long period of time. Stop an engine when it is not in use. If long idle periods are necessary, use No. 1 diesel fuel.3. Low Quality Fuel ... Test the engine using fuel according to recommendations by Caterpillar.4. Air in Fuel System ... With air in the fuel system the engine will normally be difficult to start, run rough and release a large amount of white smoke. To remove the air from the fuel system open the manual bleed valve on the fuel injection pump housing. Operate the priming pump until the flow of fuel from the manual bleed valve is free of air. Close the manual bleed valve and fasten the fuel priming pump. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the cylinder heads, and permit the fuel to come out until it is free of air. Tighten the fuel line nuts. If air is not removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.5. Fuel Injection Timing Not Correct ... Check and make necessary adjustments as per Testing and Adjusting section of this Service Manual.6. Automatic Timing Advance Does Not Operate Correctly ... Check with engine warm. Use the 8T5300 Timing Indicator Group to check the automatic timing advance unit. Check to see that the advance is smooth and that the amount of advance is correct. See Fuel System of the Testing and Adjusting section of this Service Manual for the subject Checking Engine Timing And Automatic Timing Advance Unit With 8T5300 Timing Indicator Group. If the timing indicator is not available, make rapid "acceleration" (increase in speed) from low idle to high idle. Engine must have smooth acceleration. A timing advance that does not operate correctly
Recommended Procedure
1. Cold Outside Temperatures ... When the air outside is cold, the cylinder temperature is cooler. Not all the fuel will burn in the cylinders. The fuel which does not burn comes out the exhaust as white smoke. White smoke is normal in cold temperatures until the engine operates long enough to become warm. There will be less white smoke if No. 1 diesel fuel is used.2. Long Idle Periods ... When an engine runs at idle speed for a long period of time, the cylinders cool and all of the fuel does not burn. Do not idle an engine for a long period of time. Stop an engine when it is not in use. If long idle periods are necessary, use No. 1 diesel fuel.3. Low Quality Fuel ... Test the engine using fuel according to recommendations by Caterpillar.4. Air in Fuel System ... With air in the fuel system the engine will normally be difficult to start, run rough and release a large amount of white smoke. To remove the air from the fuel system open the manual bleed valve on the fuel injection pump housing. Operate the priming pump until the flow of fuel from the manual bleed valve is free of air. Close the manual bleed valve and fasten the fuel priming pump. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the cylinder heads, and permit the fuel to come out until it is free of air. Tighten the fuel line nuts. If air is not removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.5. Fuel Injection Timing Not Correct ... Check and make necessary adjustments as per Testing and Adjusting section of this Service Manual.6. Automatic Timing Advance Does Not Operate Correctly ... Check with engine warm. Use the 8T5300 Timing Indicator Group to check the automatic timing advance unit. Check to see that the advance is smooth and that the amount of advance is correct. See Fuel System of the Testing and Adjusting section of this Service Manual for the subject Checking Engine Timing And Automatic Timing Advance Unit With 8T5300 Timing Indicator Group. If the timing indicator is not available, make rapid "acceleration" (increase in speed) from low idle to high idle. Engine must have smooth acceleration. A timing advance that does not operate correctly