Information injection-pump assembly
ZEXEL
106671-1693
1066711693
ISUZU
1156027453
1156027453
Rating:
Service parts 106671-1693 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-217-3
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Include in #1:
106671-1693
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-1693
1066711693
ISUZU
1156027453
1156027453
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
134424-1920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
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
Rack position
(12.9)
Vist
V
1.41
1.41
1.41
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
164.5
162.5
166.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Injection quantity adjustment_02
Rack position
(7)
Vist
V
2.6
2.5
2.7
Pump speed
r/min
240
240
240
Average injection quantity
mm3/st.
12
8.8
15.2
Max. variation between cylinders
%
0
-13
13
Injection quantity adjustment_03
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
130
110
130
Remarks
Set the rack limit, measure rack position and Vista.
Set the rack limit, measure rack position and Vista.
Test data Ex:
Governor 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
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=19mm bb=1mm
----------
a=33deg+-5deg b=33deg+-5deg
----------
aa=19mm bb=1mm
----------
a=33deg+-5deg b=33deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=8deg
----------
a=(40deg)
----------
aa=8deg
----------
a=(40deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------
----------
----------
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Information:
Possible Causes/Corrections
Air or Water 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. If the engine will not start, loosen a fuel injection line nut and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time until the fuel that comes out is free of air. Tighten the fuel lines nuts. If the air can not be 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 leaks 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.Water in the fuel can cause rough running and possible fuel system damage. Valve Adjustment Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in.) and exhaust valve clearance is 0.64 mm (.025 in.). Also check for a bent or broken push rod. Bad Fuel Nozzle(s)/Find a bad nozzle by running engine at the rpm where it runs rough. Loosen the fuel line nut enough to stop fuel supply to that cylinder. Each cylinder must be checked this way. If a cylinder is found where loosening of the nut makes no difference in the rough running, test the nozzle for that cylinder. To test a nozzle, remove the nozzle from the engine and test as in Testing and Adjusting section of this Service Manual. Fuel Leakage From Fuel Injection Line Nut/Tighten nut to 40 7 N m (30 5 lb. ft.). Again check for leakage. Bad Fuel Injection Pump/An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting section in this Service Manual for the correct specifications and procedure to check the plungers and lifters.Fuel pumps which are severely scored from debris can cause rough running, but fuel dilution usually occurs before horsepower is affected.Low installation torque on the fuel pump retaining nut can cause misfire, rough running and low power. Fuel Has a High "Cloud Point"/In cold weather operation this condition should be checked first. The fuel "cloud point" is the temperature at which wax begins to form in the fuel. If the atmospheric temperature is lower than the "cloud point"
Air or Water 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. If the engine will not start, loosen a fuel injection line nut and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time until the fuel that comes out is free of air. Tighten the fuel lines nuts. If the air can not be 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 leaks 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.Water in the fuel can cause rough running and possible fuel system damage. Valve Adjustment Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in.) and exhaust valve clearance is 0.64 mm (.025 in.). Also check for a bent or broken push rod. Bad Fuel Nozzle(s)/Find a bad nozzle by running engine at the rpm where it runs rough. Loosen the fuel line nut enough to stop fuel supply to that cylinder. Each cylinder must be checked this way. If a cylinder is found where loosening of the nut makes no difference in the rough running, test the nozzle for that cylinder. To test a nozzle, remove the nozzle from the engine and test as in Testing and Adjusting section of this Service Manual. Fuel Leakage From Fuel Injection Line Nut/Tighten nut to 40 7 N m (30 5 lb. ft.). Again check for leakage. Bad Fuel Injection Pump/An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting section in this Service Manual for the correct specifications and procedure to check the plungers and lifters.Fuel pumps which are severely scored from debris can cause rough running, but fuel dilution usually occurs before horsepower is affected.Low installation torque on the fuel pump retaining nut can cause misfire, rough running and low power. Fuel Has a High "Cloud Point"/In cold weather operation this condition should be checked first. The fuel "cloud point" is the temperature at which wax begins to form in the fuel. If the atmospheric temperature is lower than the "cloud point"