Information injection-pump assembly
ZEXEL
106671-6300
1066716300
ISUZU
1156031640
1156031640
Rating:
Service parts 106671-6300 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-360-1
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
106671-6300
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-6300
1066716300
ISUZU
1156031640
1156031640
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
127
127
Overflow valve opening pressure
kgf/cm2
1.3
1.3
1.3
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
11.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
140
138
142
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.4+-0.5
Pump speed
r/min
465
465
465
Average injection quantity
mm3/st.
14.5
11.3
17.7
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
1000++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1000.
Do not advance until starting N = 1000.
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
0.5
0.5
0.5
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)Set idle sub-spring
(4)Main spring setting
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Rack position = aa (speed = bb)
----------
aa=1-0.5mm bb=0r/min
----------
a=41deg+-3deg b=(23deg)+-5deg c=(4deg)+-5deg
----------
aa=1-0.5mm bb=0r/min
----------
a=41deg+-3deg b=(23deg)+-5deg c=(4deg)+-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=15deg+-5deg b=70deg+-5deg
----------
aa=1-0.5mm bb=0r/min
----------
a=15deg+-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=12deg
----------
a=(50deg)
----------
aa=12deg
----------
a=(50deg)
Information:
PARTS NEEDED
Qty
Part Number Description
6 5577633 INJECTOR GP
1 5638152 FILTER-LUBE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Upon failure of an injector or multiple injectors, replace the entire set of fuel injectors with six 5577633 fuel injectors and install a new 5638152 fuel filter.
Refer to Disassembly and Assembly, RENR9579, Unit Injector - Remove, and Unit Injector - Install.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-4000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-8000 hrs,
25-36 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 6.7-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.