Information injection-pump assembly
ZEXEL
106671-6060
1066716060
ISUZU
1156029800
1156029800
Rating:
Service parts 106671-6060 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-159-1
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
106671-6060
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-6060
1066716060
ISUZU
1156029800
1156029800
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
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
1-4-2-6-
3-5
Pre-stroke
mm
3.8
3.77
3.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 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
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
177
175
179
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
90.6
90.6
Boost pressure
mmHg
680
680
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.4+-0.5
Pump speed
r/min
385
385
385
Average injection quantity
mm3/st.
13.2
10
16.4
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
230
230
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-0.8
Boost pressure
kPa
50.7
46.7
54.7
Boost pressure
mmHg
380
350
410
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(9.8)
Boost pressure
kPa
77.3
70.6
84
Boost pressure
mmHg
580
530
630
Timer adjustment
Pump speed
r/min
1150++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1150.
Do not advance until starting N = 1150.
Timer adjustment_02
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1
0.5
1.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Boost compensator stroke: BCL
----------
K=10 BCL=0.8+-0.1mm
----------
----------
K=10 BCL=0.8+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=20deg+-5deg
----------
----------
a=2deg+-5deg b=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb (stamp at delivery)
----------
aa=1-0.5mm bb=0r/min
----------
a=53deg+-5deg b=70deg+-5deg
----------
aa=1-0.5mm bb=0r/min
----------
a=53deg+-5deg b=70deg+-5deg
Timing setting
(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=14deg
----------
a=(70deg)
----------
aa=14deg
----------
a=(70deg)
Information:
Image1.1.1
Image1.1.2
Image1.1.3
Image1.1.4
Image1.1.5
Image1.1.6
Image1.1.7
Image1.1.8
Image1.1.9
PROCEDURES FOR DPF MODULE REWORK
PROCEDURE ( A ) See Image 1.2.1
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.
PROCEDURE ( B ) See Image 1.2.2
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.
PROCEDURE ( C ) See Image 1.2.3
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.
PROCEDURE ( D ) See Image 1.2.4
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.
PROCEDURE ( E ) See Image 1.2.5
Butt weld ring flush to retainer ring on inlet assembly in 4 spots.
Fillet weld 2 pins (at 0 and 180 degree orientation) to outlet side of DPF's 300 mm from each other.
Drill 5/8" holes in the outlet assembly flanges 300 mm from each other.
Place tube flush to the flange inside this hole and weld to outlet assembly.
PROCEDURE ( F ) See Image 1.2.6
Position plates (at 0 and 180 degree orientation) to outlet side of the DPF flange.
Allow plates to extend ( minimum 1/4 inch ) past outer edge. Using slots in plates
weld into place.
PROCEDURE ( G ) See Image 1.2.7
Fillet weld (3 mm weld size) 2 pins (at 0 and 180 degree orientation) to outlet side of DPF 260 mm from each other.
Drill a 5/8" hole in the outlet assembly flange 260 mm from each other 13 mm deep.
Place tube flush to the flange inside this hole and weld to outlet assembly.
PROCEDURE ( H ) See Image 1.2.8
Fillet weld 2 pins (at 0 and 180 degree orientation) to outlet side of both DPF's 300 mm from each other.
Drill 5/8" holes in the outlet assembly flanges 300 mm from each other 13 mm deep.
Place tubes flush to the flange inside this hole and weld to outlet assembly.
PROCEDURE ( I ) See Image 1.2.9 and Image 1.2.10
Remove the clamp and gasket from DPF inlet side.
Mate inlet flange to DPF without gasket or clamp.
Tack weld in place.
Apply a continuous weld to the inlet flange/DPF seam.
Image1.2.1
Image1.2.2
Image1.2.3
Image1.2.4
Image1.2.5
Image1.2.6
Image1.2.7
Image1.2.8
Image1.2.9
Image1.2.10
Filter Module Cross Reference Guide See Image 1.3.1.
Image1.3.1